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    "Garment Production System": K. M. Sunjib Anwar MBA, SCSS

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    This document discusses and compares three garment production systems: Progressive Bundle System (PBS), Unit Production System (UPS), and Modular Production System (MPS). PBS is the most traditional system, involving bundling cut garment parts and moving them between workstations. UPS uses overhead carriers to transport all parts for a single garment together through the assembly process. MPS organizes workers into empowered teams responsible for portions of the production process. Each system has advantages like labor utilization or flexibility, and disadvantages like costs or planning needs.

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    "Garment Production System": K. M. Sunjib Anwar MBA, SCSS

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    sailuziam
    67 views19 pages
    This document discusses and compares three garment production systems: Progressive Bundle System (PBS), Unit Production System (UPS), and Modular Production System (MPS). PBS is the most traditional system, involving bundling cut garment parts and moving them between workstations. UPS uses overhead carriers to transport all parts for a single garment together through the assembly process. MPS organizes workers into empowered teams responsible for portions of the production process. Each system has advantages like labor utilization or flexibility, and disadvantages like costs or planning needs.

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    This document discusses and compares three garment production systems: Progressive Bundle System (PBS), Unit Production System (UPS), and Modular Production System (MPS). PBS is the most traditional system, involving bundling cut garment parts and moving them between workstations. UPS uses overhead carriers to transport all parts for a single garment together through the assembly process. MPS organizes workers into empowered teams responsible for portions of the production process. Each system has advantages like labor utilization or flexibility, and disadvantages like costs or planning needs.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    67 views19 pages

    "Garment Production System": K. M. Sunjib Anwar MBA, SCSS

    Uploaded by

    sailuziam
    This document discusses and compares three garment production systems: Progressive Bundle System (PBS), Unit Production System (UPS), and Modular Production System (MPS). PBS is the most traditional system, involving bundling cut garment parts and moving them between workstations. UPS uses overhead carriers to transport all parts for a single garment together through the assembly process. MPS organizes workers into empowered teams responsible for portions of the production process. Each system has advantages like labor utilization or flexibility, and disadvantages like costs or planning needs.

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    GARMENT

    PRODUCTION
    SYSTEM
    BY:
    K. M. Sunjib Anwar; MBA, SCSS

    Garment Production System


    In simple a garment production system is a way how
    fabric is being converted into garment in a
    manufacturing system.
    The choice of best apparel production system depend on
    the Product, The Policies of the Company and the
    capacities of manpower.
    There are basically three Production systems:
    I. Progressive Bundle System
    II. Unit Production System
    III. Modular Production System

    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 Workflow
    Bundles 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.

    Progressive Bundle System

    Advantages of PBS
    Labor 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.

    Dis-advantages of PBS
    Time Consuming due to assembling, moving and untieing of bundles.
    More laborMore labor cost.
    Needs efficient supervisor.
    Labor absentiees can effect production due to
    incompletion of contracts.
    Variety of styles and less quantity is not effective in this
    system.
    Proper planning is required for each style, each batch.
    Improper planning causes labour turnover, poor quality,
    less production, etc.

    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.

    UPS Workflow
    Load all the pieces of single garment in a product
    carrier.
    The product carrier with the pieces will be routed
    through the different operation steps.
    At every machine/operation the patented chain will
    position the product ideally.
    Completed the product arrives to an unloading
    station. The empty product carrier returns to the
    loading station.

    Unit Production System

    Advantages of UPS
    Bundle 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 UPS

    Unit 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 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.
    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.

    Modular Production System

    Team members develop an interdependency to


    improve the process and accomplish their goals.
    A worker in a team can perform Multiple functions
    depending upon his skills (Multi-skills).

    Modular Production System

    Advantages of MPS

    1) High Flexibility.
    2) Fast throughput times.
    3) Low wastages.
    4) Reduced absenteeism.
    5) Empowered employees.
    6) Improved Quality.

    Dis-advantages of MPS

    A high capital investment in equipment.


    High investment in initial training.
    No compatibility between team members can
    cause problems thus loss in production
    Dependency on the Team for whole Production.

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