Assembly Line Vs.

Modular System
A comparison on reality grounds

Introduction- A lot has been written and discussed about various

manufacturing systems in apparel industry. Different experts have different opinions on advantages and disadvantages of one system on another. But most of the times we miss to cover all aspects altogether and thus unable to realize or visualize the actual picture, which takes shape after a break through change in the manufacturing set-up. Most of the times these big decisions are taken without a proper analysis and it results in big disasters.

This article is an effort to have a comparison of Assemble Line to Modular Line on reality grounds, which will help us in opting the suitable manufacturing system for the plant.

Money matters more and it plays much more important role when you are dealing in apparel sector, as competition is growing faster resulting in everyday shrinking margins.

For any business below factors play vital roles1. Man 2. Machinery 3. Space The ultimate objective is to have the best utilization of above all, so that the profits can be maximized.

Manoj TiwariUser

Assembly Line Vs. Modular System

A comparison on reality grounds
A good amount of literature, experts comments and consultants views advocating the benefits of Modular manufacturing are available. So first lets have a crux of thatModular manufacturing is a type of Flexible manufacturing systems, which provides Faster and efficient through put and better balancing of work by keeping lower WIP and needing less space. The Modular system enhances multi skill development of operators, which helps in quick response to style change with achieving quality standards. Apart from above, it increases team spirit which helps organization in improving work environment.

Now lets try to have a detailed comparison of Assembly line system to the Modular on ground realities. (For comparison and calculations the product taken is 5- Pocket Denim Jean, Assumed SAM-14.0 min. /Garment) Type of Salary/ Requirement Assembly Manpower Month for required (Indian Line (Nos.) Rs.)* Sewing Operator Iron man Quality Checker 3000 5000 1 7 1 -- * 3000 35,000 3000 -6000 40 Requirement for Modular System (Nos.) 20 Cost/Month (Indian Rs.) for Assembly Line 240,000 Cost/Month (Indian Rs.) for Modular System 120,000

Manoj TiwariUser

Assembly Line Vs. Modular System

A comparison on reality grounds
Helper Trimmer Supervisor 2500 3000 10000 11 2 2 -- * -- * 1 27,500 6000 20,000 --10,000

Total

63

22

331,000

133,000

*- As per the modular manufacturing philosophy- there should be NO checkers, helpers

And Trimmers, hence all these activities have to be done by the Sewing operator itself.

*- Salary figures are tentative.

Considering 8 Hrs. shift/Day, total available minutes/ shift will be 480.0 Min.

SAM given is 14.0 Minutes, which includes- times for Ironing, Quality Check and Trimming activities.

Production calculation for Assembly Line So, as per the above table, manpower required for Assembly line will be= 50

Expected Out put per shift @ 65% efficiency= (50X480)*0.65/14.0 = 1114 Units/ Shift

Total Labor Productivity (Assembly Line) = 1114/63 = 17.68 Units/Person/Shift

Production calculation for Modular System Expected Out put per shift @ 65% efficiency= (21X480)*0.65/14.0

Manoj TiwariUser

Assembly Line Vs. Modular System

A comparison on reality grounds
= 468 Units/ Shift Total Labor Productivity (Modular System) = 468/22 = 21.27 Units/Person/Shift Expenditure on wages/ Day (assuming Avg. 30 days in one month) for Assembly Line - 331,000/ 30 = INR. 11033 /Day

Cost / Garment for Assembly Line = 11033 / 1114 = INR. 9.9039 / Garment

Expenditure on wages/ Day (assuming Avg. 30 days in one month) for Modular System 133,000 / 30 = INR. 4433 /Day

Cost / Garment for Modular System = 4433 / 468 = INR. 9.4729 /Garment

Gain / Garment by using Modular system over Assembly Line-

INR. 0.4309 / Garment

Prima-facie opting Modular System over Assembly Lines seems a good deal, but I suggest you to dont go with this asMark Twain said- There are three types of lies- lies, damn Lies and STATISTICS

The same may happen here also, as we have not covered some crucial factors, which may directly or indirectly affect this statistical figure.

Manoj TiwariUser

Assembly Line Vs. Modular System

A comparison on reality grounds
These factors are1. Machine usage Vs. Idle Machine cost 2. Consistency in quality of the sewn product 3. Consistency in Production/Day 4. Space Utilization 5. Operators mentality

Lets discuss all above points one by one-

1. Machine usage Vs. Idle Machine cost- In a modular system machine to man ratio is always kept more than 1, so that the multiskilling can be utilized efficiently. It means there are always some machines idle at any given point of time. Generally for a 5-pocket jean modular set-up, we use 25 machines over 20 Sewing operators; hence 20% of the total machines are always kept idle. Keeping the sewing machine Idle is definitely a cost, and it shows somewhere we are not properly utilizing the available costly resources, if we calculate straight, by working with 8 Modules for a 5-Pocket jean , we are using (unknowingly) 40 extra machines, by which you can successfully run an assembly line.

The another important point, incase there are small orders of different styles (For example- One style having asymmetric Back), in this case clubbing of machines is not possible due to frequent change in machine settings and we have to go for separate machines for each module.

Manoj TiwariUser

Assembly Line Vs. Modular System

A comparison on reality grounds
Assigning/allocating 2 different separate machines for individual modules is a costly affair and at the same time machines are not fully utilized referring to their capacity.

2. Consistency in the Sewn Product quality level- Believing in the Modular manufacturing concept for garments, the quality of sewn product has to be ensured by the modular team itself, there is NO quality check as each operator is responsible for checking and rectification in the product if required), there is provisions for audits only, once out put is done. In this scenario when there is production pressure, operator misses to check the quality (uncut threads, wrong sewing margins, unmatched notches, and wrong parts attachment is very common problems). As there is only final audit in modular system, till the time you come to know about poor quality of the product, a big loss of time, material and money has already been done, which results in cost of poor quality. Producing and making things wrong are bigger losses than less/no producing.

3. Consistency in daily production- Lets assume on a fine day 1 modular operator, who is trained for 3 operations in absent. Unfortunately if he is a crucial operator expert in Inseams or waist band attach, the production and productivity of that day for that module is in serious danger.

Manoj TiwariUser

Assembly Line Vs. Modular System

A comparison on reality grounds
In a country like India, where festive seasons, health issues and climatic calamities are very often, this scenario of key operators absent is very normal. Here as a replacement you are left with two options, either use a multiskilled operator from somewhere else or use three different operators for these operations, both the solutions are going to add extra cost to the process with no guarantee of achieving required quality level. At the same time if this operator absence scene happens in assembly line, you have to deal with one and only one operator, who does only one operation and finding out a replacement for it, will not be a big deal for you.

4. Space Utilization- In general practice for a 5- Pocket jean, the space

consumed by 2 modules is equal to 1 Assembly line. Apart from it, we have to provide space for sewing preparatory for individual module and space for the non productive or idle machines in the module. It has been observed that on an average a module takes 2 years to get matured, till that time you have to compromise with daily avg. production of 250-300 Pcs ./Day ( against 468 Units/Day as calculated above @ 65% efficiency) and in the same conditions a line starts producing out put Avg. 1100 Units/Day(As calculated above) from 8th or 9th day of the line starts. It means from a space of 2 modules, we will get approximately avg. 500-600 Units/Day out put, which is equivalent to a space of a line, whereas from a line you can get easily 1100 Units/Day.

Manoj TiwariUser

Assembly Line Vs. Modular System

A comparison on reality grounds

Hence its clear that, to get equivalent out put to an assembly line, we need infect 4 modules (Equal to the space of 2 lines), it shows somewhere we are loosing space and not unable to get a logical out put from the given space. Space is definitely a big cost, and the above results show better to have an assembly line over modules. 5. Operators mentality- This is one of the most crucial factor which decides the future performance of any manufacturing system. But most of the times we skip this point taking as a secondary priority. This is a well known fact that operators training and making them multi- skilled takes a good amount of time, resources in terms of money and manpower as well as managements patience also. Now lets think about this concept of multi-skilling from operators mind set, he may think below two pointsA. Why he should learn different operations or different works when salary is going to be more or less same. Multiskilling will put extra burden on him without giving no significant monitory benefits. B. OK, he will learn more than one or two operations and will become a multi skilled operator, but as soon as he learns all this, he will leave this job and join another company who can pay him better.

In both the cases, the MANAGEMENT who invested so much time and everything in the operator training and multi-skilling is the LOOSER.

Manoj TiwariUser

Assembly Line Vs. Modular System

A comparison on reality grounds
These scenes dont occur to such a scale while we are working with assembly line.

Conclusion- From above discussed points, its clear that such a strategic
decision like converting a set-up from Assembly line to modular or vis-versa may decide the future of the plant and a good deep thought or brain storming considering all the aspects should be done before decision making. No doubt, there is nothing left all across the globe for modular systems to prove further. Their success stories reveal the uniqueness and excellence right from automobile sector to apparels.

Modular philosophy has its own advantages and benefits, but the requirement is to run modules with discipline and religiously. There must be no compromise with fundamentals; otherwise blind follow-up of modules may come up with bigger disasters.

Manoj TiwariUser