Production Systems & Performance Measures

Apparel Production Systems Production System?Apparel Production SystemTypes Of Apparel Production SystemMake Through SystemModular Production System Assembly Line SystemProgressive Bundle SystemUnit Production SystemSelection of Apparel Production System Q&A SessionContentsSYSTEM? A group of interdependent items/processes that interact regularly to perform a taskSYSTEM:Transformation of resources into useful goods and services through continuously interdependent processes.

A production system takes inputs and converts them into outputs.

Production SystemHow to manufacture an apparel?

What is an apparel production system?DiscussionAn apparel production system is an integration of 5 interdependent Ms (Man, Machine, Material, Method & Money) that directs work flow and generates finished products.Apparel Production SystemMake Through SystemModular Production SystemAssembly Line SystemProgressive Bundle SystemUnit Production SystemNote: Firms may use only one system or combination of systemsIt is the traditional method of manufacture in which normally an operator makes right through one garment at a time. That is one operator will do all the stages of the sewing operations of one garment and after completing it he will go for the next garment

1. Make Through SystemThe advantages of make through system are

Quick throughput time

Easier to supervise

Reduced WIP levels as compared to other production systemsAdvantages Low productivity

High labor cost

Only very experienced operator can be used

It is a system only suitable in high fashion and sample makingDisadvantagesAssembly lines are designed for a sequential organization of workers, tools or machines, and parts. The motion of workers is minimized to the extent possible.

Each operator is assigned only one operation in this system

Garment components are moved from operation to operation.

2. Assembly Line systemPlace the tools and the men in the sequence of the operation so that each component part shall travel the least possible distance while in the process of completion.Use work slides or some other form of carrier so that when a workman completes his operation, he drops the part always in the same place-which place must always be the most convenient place to his hand and if possible have gravity carry the part to the next workman for his operation.Working Principles of Assembly LineUse sliding assembling lines by which the parts to be assembled are delivered at convenient distances.

There are two variations of the assembly line system being followed in the industries namelyProgressive Bundle systems andUnit production system.

Working Principles of Assembly LineParts of various component after being cut in the Cutting Room are tied up in bundles and distributed out to the Sewing Section. This is called the Progressive Bundle System (PBS).(a) Progressive Bundle System(PBS)PBS

Bundle Tickets attached to cut parts.

One operator is expected to perform the same operation on all the pieces in the bundle.

Retie the bundle and set it aside until it is picked up and moved to the next operation.

PBSLabor of all level used, cost of labor is cheapSpecialized and Rhythm of operation increase productivityAllow better utilization of specialized machines.Advantages

High Production outputs.There is less chance of shade variation, size variation. Bundle tracking is possible, so identifying and solving the problems becomes easy.

AdvantagesSlow Processing.Balancing the line is difficult.Increase in WIP in each section increases the inventory cost.The system is not very adaptable for short run production and frequent style changes, as these require rearrangement of the workstation

Disadvantages

20It requires high level of management skills.Improper planning causes labor turnover, poor quality, less production etc.Individual operators that work in a progressive bundle system are independent to others.

DisadvantagesA study by industrial engineers in Sweden over 30 years ago showed that operators were only spending 20% of their time actually sewing.

The rest of the operator's time was spent in handling materials and dealing with personal fatigue issues.

(b) Unit Production SystemThe Unit Production System is usually but not always an overhead conveyor, which moves the single product between workstations

Unit Production System provides for improved efficiency, by eliminating highly unproductive material handling procedures

The underlying theme was to create a smooth workflow and effectively utilize both the workers and equipment

Unit Production System(UPS)How It Works:*. Load all the pieces in a product carrier.

From bundle to unit

UPS

To help increase productivity, an overhead conveyor system was designed, containing barcoded hangers.The flexible chain is easily adjusted and can position units for drop-off directly at the needle point. All the pieces of one unit are included in an individual hanger, and each unit can be pinpointed throughout the manufacturing process.

UPSUnit production systems in ETON are linked to a computer control center that routes and tracks production and provides up-to-the-minute data for management decisions.

The need for bundle tickets and processing operator coupons is also eliminated.

Unit Production System.mp4

UPSIncreased productivity Improved lead times with less work-in-process Improved production and quality monitor Improved ergonomics keeps the factory floor clear Direct & Indirect labor costs reduced

Advantages28High cost of installing Specialized training for the system Down time is a potential problem

DisadvantagesA group of operator work together to make product from start to finish .The number of employees on a team, usually 4 to 15, vary with the product mix.Component of one garment are fed into flow.

3. Modular Production SystemMPS

MPSIRON / PRESS

Jn Tk Elastic to Body (S/N)

14

Attach Elastic to Body (O/L)13Out Seam , O/L Pkt Bag (O/L ) 9 , 10

Back Rise (O/L)7

T/S Front/ Back Rise(S/N)6,8Att Pkt Bag to Frnt & Pkt Bag to Back (S/N)2,4,Fcng Att to Pkt Bag/mouth (S/N) (4)

1,3Front Rise (O/L)

5Inseam (O/L)

11Button Hole

12Stitch Waist Band (SM)

15Hem Bottom (S/N)(Swing Folder)16

INSPECTION

BIN

TAG / POLYBAG

Team members cross-trained and interchangeable among tasks within the group. Teams may be used to perform all the operations or a certain portion of the assembly operations depending on the organization of the module and processes required.

MPSOperators are given the responsibility for operating their module to meet goals for throughput and quality.The team is responsible for maintaining a smooth work flow, meeting production goals, maintaining a specified quality level, and handling motivational support for the team.Team members are Interdependables.

MPSA Modular Production System operates as a Pull System, with demand for work coming from the next operator in line to process the garment.Modules frequently operate as minifactories with teams responsible for group goals and self-management.

MPSMODULES WORK ON PULL SYSTEM;LINES WORK ON PUSH SYSTEM.

High flexibility Fast throughput times Solves absenteeism related problemsIncreased employee ownership of the production process Empowered employees Improved Quality

AdvantagesHighly skilled operators required High investment in initial training High cost incurred in continued training Its difficult for team to accept new member

DisadvantagesKnown by many names Flexible manufacturingSelf directed work teamsCellular manufacturing units

Better suited to small & Medium production runs

Modular Production System

Any system Can be evaluated on following PointsThroughput time Employee Attitude Costs Indirect Labor Ratio Labor Turnover Quality

Performance MeasuresMaterial=Short Sleeve Crew Neck T ShirtQty=1000 pcsShift Time=450 minStandardized ParametersFindingsParametersPBSMPSUPSThroughput7 Days3 days2 daysWIPHighLowLowSqr.ft/opt.8.5 m25.5 m25 m2Efficiency49%80%88%Fault%7.2%2.5%1%QualityGoodExcellentExcellentLabor costLowHighHighIndirect labor costHighLowVery lowAbsenteeism5%3%2%Training costLowHighMore ExpensiveEmployee AttitudeCompetitiveCooperativeCooperativeResponsibilityPoorExcellentMediumFlexibilityPoorExcellentExcellent43How to Select an Appropriate Apparel Production System?There are 3 elements in selecting an apparel production system.

Compare Apparel Production Systems.

Evaluate Apparel Production System.

Select Apparel Production System Most Appropriate for Company Requirements.Elements And Performance CriteriaPERFORMANCE CRITERIA: Comparative system features are outlined.RANGE: Skill level, Operator flexibility, WIP, Throughput time.

Systems are compared in terms of space and equipment requirement for different products. RANGE: trousers and skirts, shirts and blouses, sweat and T shirts, lingerie, dresses, jackets

1 Compare Apparel Production SystemPERFORMANCE CRITERIA:Systems are evaluated in terms of their suitability for different products.Systems are evaluated in terms of their suitability by production quantity.RANGE: Quantities 1-10, 11-100, 100-500, over 500.Systems are evaluated in terms of system purchase, installation, and running costs.Systems are evaluated in terms of flexibility of production.

2. Evaluate Apparel Production SystemPERFORMANCE CRITERIASystem is selected according to company requirements.Throughput times on selected system meet company requirements.Implementation requirements are detailed.

RANGE: Training, space requirements, machinery and/or equipment, time scale.

3. Select Production systems Most Appropriate for Company Requirements.Any Query.?Thanks