Bundling and ticketing

Bundling and ticketingBundling" is the process of disassembling the stacked and cut pieces and reassembling them in production lots grouped by garment unit, colour dye lot, and number of garments.

Manufacturers use a variety of bundling methods depending upon their needs.

Four basic systems being the most common among manufacturers.

Group bundling

Progressive bundling

Item bundling

Unit production system (UPS)

Modular or "team based

1. Progressive Bundle System (PBS)Also Called Material Handling System.As name implies the bundle of garment parts move from operation to operation.Traditional Production system.Widely used by apparel manufacturers for several decades and still today.80% apparel manufacturers use the Bundle system (PBS).

PBS WorkflowBundles consist of garment parts needed to complete a specific operation (e.g an operation bundle for pocket setting might include shirt fronts and pockets to b stitched together.Some firms operate with a standard bundle size, while other vary bundle sizes acc. to size of pieces in bundle and operation to b completed.Bundles are assembled in the cutting room, where cut parts are matched up with corresponding parts and bundle tickets.Workers (labour) transport and move Bundles of cut parts to sewing room via trollies.Operator scheduled to complete the operation and perform same operation on all pieces in the bundle, retie the bundle, remove Bundle ticket and move bundle for next operation. Advantages of PBSLabor of all levels ie unskilled, skilled, semi skilled labors are involved. Small simple operations.Quantity of each operation is checked during every single operation thus quality is good.Due to bundle system, less chance of mixing up of partsthus less confusion.Bundle tracking is possible, so identifying and solving problems become easy.Effective production control system and Quality control system.

2. Unit Production System (UPS)A Unit Production System is a type of layout that uses an overhead transporter system to move garment components from work station to work station for assembly.In UPS, there are hangers. One hanger have multiple clips containing all parts of the single garment.All parts for the single garment are advanced through stitching line together by means of hanging carrier that moves along an overhead conveyor.Hanging carrier can be moved manually by the operator using button after completion of single operation or By computerized system that move the conveyor after a specific fed throughput time. Advantages of UPSBundle Handling completely eliminated.The time involved in the pick-up and disposal is reduced to minimum.Output is automatically recorded, eliminates the operator to register the work.The computerized system automatically balance the work between stations.Improved lead times-less work in process.Improved space utilization (more machines can be adjusted)

Advantages of UPS (Cont.)Increased Productivity.Throughput time can be drastically reduced.Indirect labor costs are reduced (by elimination of bundle handling and requiring fewer supervisors)Improved production and quality.

Dis-advantages of UPSUnit Production system requires high investment.Proper planning is required to be effective.Highly expensive-buying equipment and cost of installing.Specialized training for the system. 3. Modular Production SystemA 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.Usually there are 4-15 labors in one team depending upon the type of garment to be stitched and skills of labor.Teams may be used to perform all the operations (whole garment production) or certain portion of assembly operations.Team is responsible fro maintaining a smooth work flow, meeting production goals, quality level.Bundle ticket Bundle ticket also known as work or pay control ticketOriginates in either cutting department or the pay-roll departmentUsed for pay control as well as production control processCan be used for unit flow as well as bundle flow production systemsAll bundle tickets have Two major sections:One is Returned to payroll control by production supervisory staffSecond is submitted by the operators

In sectionalized production system bundle ticket Is perforated in sections and sub-sections according to the total number of sub assembly and assembly lines as well as the number of jobs in them.

Thus two divisions are formed out of the bundle ticket :Supervisory divisionSub-section which each operator takes

Each of the supervisory division contains: Serial number of the entire bundle ticketThe name of the sub-section, such as sleeve, collar, front, etc.Style name or numberCutting order number or spreading ticket number (move ticket number)The date the bundle was compiled in the cutting departmentSize, amount, color of the bundleName of each job in the section and the number of the operator who did the job, next to each job name, also the date the operation was completed.The signature of the supervisor or checker for the production section covered by the ticket section.

Each of the operators sub-section contains:Name of the jobBundle ticket numberThe amount, size and color of the bundleThe price of jobThe style name or numberThe move ticket number controlling the bundle (or the cutting ticket number)

There should be only one copy of each bundle ticket (with the same bundle ticket serial number), otherwise it would be impossible to prevent payment twice for a given task.

The purpose of bundle tickets is to:Monitor the progress of each specific garment,Ensure that the correct parts are assembled together, andCompensate operators for their work on each garment.

Bundling Works best for the work station layout which permits the bundler to sort withA motion pattern devoid of backtrack or criss-cross movementsMinimum distance from stack to stackManner of folding or superposing the plies in the bundles should be such that there isMinimum or no creasingMinimum or no disarraying of the cut alignment

Tier stack bins (or boxes) on casters- excellent means for bundling and transporting cut sections without the necessity of bundle tying.

The sorted stack should be packed between two plies of masonite or appropriate cardboard.

Perfect quality and securement can be had byMaking the bundle board slightly larger than the pattern areaSecuring the sides of the board with outside latches

Off LoadingOff loading is the process of removing cut parts from the cutting table, counting, ticketing, and grouping them.

Cut parts are considered work-in-progress inventory and are counted and tracked through the rest of the production processes.

This is usually done through bundle tickets that originate with cutting orders. Cut part identification involves identifying and marking parts for further operations.

Throughout the sewing process, it is essential that each garment be assembled from parts that have been cut from the same ply of fabric, which is ensured by shade marking each piece in the lay.

Every piece is ticketed with a style number, size, and ply number.

Shade marking is done prior to bundling.