UNIT PRODUCTION SYSTEM

By

Shaheerah Tazeen
Hafsa Azhar Tmm-4 15 th Dec, 2011

OUTLINE
Production systems

What is Unit Production System(UPS)?

Its Invention-Eton Mechanics Traditional Production Systems Comparison between PBS,MPS AND UPS Advantages and Disadvantages How successful is Unit Production System Conclusion References

Production Systems
An integration of material handling,

production processes, personnel, and equipment that directs work flow and generates finished products.
Several types of production systems are

available and the product characteristic is highly related to the type of production system.
The best apparel production will

depend on the mission and policies of the manufacturing firm as well as the capacities of the personnel engaged in the production departments; it also depends on the volume of production.

Production Systems

Production Systems

Figure 1. Progressive Bundling System

Figure 2. Modular Production System

Figure 3. Unit Production System

What is Unit Production System (UPS)?

In an unit production system, a garment is moved

automatically through the overhead hanging system which is controlled by the computer. It is designed ergonomically to minimize handling and manual transportation. It enhances the productivity and guarantees a premium workflow.

Types of UPS
There are two types of UPS;

Unit Production System

Manual Unit System

Automatic Unit System

1.MANUAL UNIT PRODUCTION SYSTEM

In Manual UPS labor uses hand to move conveyers to the next station when

one operation is completed.

Its structure is like railway lines which passes through all railway stations,

in the same way all the conveyers lines passes through all sewing machines.
In manual UPS we can skip any machine by changing the main track of

conveyers.

2-AUTOMATIC UNIT PRODUCTION SYSTEM

All the components for one garment are loaded

into a carrier at a workstation. The carriers is divided into section having quickrelease clamp on each. When a batch of garment has been loaded into carriers they are fed past a electronic device, which records the numbers of the carrier and addresses it to its first destination. These carriers are then fed onto the main powered line, which continually circulates b/w rows and is connected to each workstations by junctions. When operator completes his work than he press the button on the side of sewing machine, which directed carrier to the main line. Data collection system recorded the data each time when carries leaves the station.

What Happened .??

In the mid 1960s, the Swedish apparel industry was

experiencing a number of cost related problems. Lead times were too high causing:

Demands for quicker delivery times that could not be met. Garment workers were forced to waste time in handling and transporting material. Capital was needlessly tied up in work-in-progress. Higher wages . Technological advances. Changes in industry as a whole.

These above factor caused the Eton Shirt Company to

address these inefficient material-handling procedures.

EUREKA..
Inge Davidson, self-trained technician and co-

owner of the Eton Shirt Factory. He designed a creative hanging conveyor system that didn't waste valuable floor space and required no major modification to existing machines. It was simple, effective, and brilliant. The factorys efficiency increased immediately. Not only did productivity improve, but production could now be planned and controlled down to the finest detail.

The mechanics of Eton System (UPS)

The Eton system is a computerized overhead conveyer with workstations. The system eliminates manual transportation between workplaces as well as non-productive operator time. It is built from modules, which makes it very easy to adjust for every customer's specific needs. It Consist of five main working processes:
1.

Loading Station

2.
3. 4. 5.

Work Stations
Head Rail Electronic Line Control(ELC) Quality Control and unloading

LOADING STATION

Work Station

Head Rail

Electronic Line Controller

QC & Unloading

Traditional Methods
Progressive Bundle Handling(PBS)
Gets its name from the bundles of garment parts that are moved

sequentially from operation to operation. This system, often referred to as the traditional garments production system, but still several decades and still is today This method requires bundle to be transported to individual sewing operators. Sometimes, factory porters/helpers are hired to do this transporting work. But usually, the operators have to stop and leave their workspace to look for the bundles. This is an INEFFECTIVE practice, as production managers are unable to manage or plan the production effectively.

Traditional Methods
Modular Production System A modular production system is a contained, manageable work unit that includes an empowered work team, equipment, and work to be executed. The number of teams in a plant varies with the size and needs of the firm and product line in garments and so the success of this type of garments operation is in the flexibility of being able to produce a wide variety of products in small quantities in garments. The overall objective is to provide a production methodology which will enable entire production system to be rapidly designed and configured for a wide range of consumer products with minimal delay, costs and need for specialized machinery.

Comparison between PBS and UPS

Parameters

Progressive Bundle Handling

Manual transportation, many times helper are hired for this bundle transportation job.

Unit production System

Transportation

-In this system an automated mechanical system carries pieces to each work stations.

-Operators stop their work to fetch bundles.

-Easier pick up and dispose at each work station. Resulted quick response time

-Less effective in terms of production management. Resulted long response time.

Cutting Work

As a result of High Work In Process (WIP) is required by sewing section, cutting sections are required to perform 60-70% more than actual production can handle.

Lower WIP results in less cutting works. A balanced flow of material established in between cutting and sewing line.

Parameter

Progressive Bundle System

Unit production System

Through-put Time

Compare to UPS, through put time longer in PBS. How much long will depend on the bundle size and no. of bundles kept in between two operators.

Through put time in UPS is less compare to PBS. But it is not the minimum time as in this system there is WIP in between two operators.

Work In process(WIP)

In PBS generally operators are asked to sew as much pieces as they can without considering back and front operators. This resulted piling up of work in the operations with higher work content.

Less WIP in between operators. As workstation has limit of holding no. of hangers. Also after completion of operation hangers are transported to the next operation automatically.

Direct labor Content

Direct labor content is high because usually operator does tying and untying of bundles, positioning components, pulling the bundle ticket and handling of work pieces.

Direct labor content is less than PBS because an operator only sews the garment part rather than other tasks. In this system garment parts are held by the over head hanger, so less handling of garment components.

Inventory Level

Due to high WIP and cutting ,fabrics and trim has to be stocked before hand

Less inventory for fabric n trims

Advantages
Through-put time is reduced as the work in process levels

are minimized. Quality is improved Labor cost is reduces by elimination of bundle handling Less rejection Automatic counting Increase productivity Easy shifting of panels through each operation All the activity data can be easily transferred to the companies Management Information System

Disadvantages
Huge amount of cost is required in installing the UPS

Specialized and skilled training system and employees

required Hard to make small parts such as loops, zipper and pockets

Success
Let seehow successful UPS it is through out the

world.

Conclusion
In today's ever changing market conditions, UPS is

a system that you can rely on. The system provide the apparel units to utilize their existing recourses in a much better way. It provides ergonomic benefits that directly translate less fatigued operators and improved productivity. This system helps the production line to work proactively, solving problem before they occur, making comparative analysis, identifying bottleneck signs and reading visual clues to take immediate action.

References
http://www.eton.se/oldsite/CompanyFacts/AboutUs.h

tml http://www.eton.se/oldsite/TheEtonSystem/Articles/TC2. pdf http://www.iigm.in/pt_eton.html http://www.iigm.in/pt_e_es.html http://www.iigm.in/pt_e_wt.html http://www.onlineclothingstudy.com/2011/02/comparisonbetween-progressive-bundle.html http://forum4.aimoo.com/worldtextile/Textile-ApparelApparel/Progressive-Bundle-System-1-128948.html http://fibres2fabrics.blogspot.com/2011/05/apparelgarments-production-systems.html

Thank You!!