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10a...Apparel Production Systems

10a...Apparel Production Systems

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Published by Abhinav Verma
Knitwear Production Planning and Control
Knitwear Production Planning and Control

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Published by: Abhinav Verma on Jun 10, 2013
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Knitwear Production Planning & Control
Apparel Production Systems
Apparel Production Systems an integration of materials handling, production processes, personnel, and equipment that directs work flow and generates finished products.Apparel Production Systems an integration of materials handling, production processes, personnel, and equipment that directs work flow and generates finished products.Most of the production systems employed in garment factory are derived from
Manual systemsMaking Through (Manual system)Section or Processes SystemProgressive Bundle System (PBS)Straight-line or Synchro- system
Mechanical systemsSelective Conveyor Belt SystemUnit Production System (UPS)Quick Response Sewing SystemModular Production Systems (MPS) ( Each production system has its own specific operational characteristics )1.
Manual system
(Making Through)This is essentially traditional method of production – the entire garment is assembled byone operator.This type of system is effective when a very large variety of garment have to be producedin extremely small quantities.Example - sewing room of a boutique.Major features of the system are;Supervision :- The requirement are minimal because the operators deside on their ownworking methods.Labour:- As highly skilled labours are used for the simplest of operations, cost arerelatively high when compared with other systems.Quality:- high quality is required.Sept 2010 Intro to Indian Apparel Sector1
Knitwear Production Planning & ControlProductivity:- due to lack of specialization, this system is not effective for high volume production.Throughput Time:- it is not necessary.Layout:- Any convenient arrangement of machinery.2.
Section or Processes System
Operators specialize in one major component and sew it from beginning to end.The sewing room would have a number of sections, each containing versatile operatorscapable of performing all the operations required for a specific components. The sectionsare built according to the average garment produced, and includes;
Pre-assembling (preparation of small parts)
Front making
Back making
main-assembly (closing, setting collar and sleeves,..)
Lining making
Setting linings
Finishing operationspecific operational characteristics are:-Sept 2010 Intro to Indian Apparel Sector2
MakingSmallcomponentMakingbackMakingFrontFinishSetCollarsAndsleevesClosingBacks& Front
Knitwear Production Planning & ControlSupervision :- this has to ensure the correct movement of work from section to section.Labour:- As labour with varing skills can be used , the system is cheaper.Quality:- due to the various levels of operator skill, in-process quality contro has to bevery thorough.Productivity:- higher than the manual making through system.Throughput Time:- this is longer due to the large quantities of work in process.Layout:- this would be planned according to the processs folw of the average garment produced.This is a very efficient system for producing a variety of styles in reasonable quantities.3.
Progressive Bundle System (PBS)
A traditionally employed in apparel production where the task of assembling the garment is broken down into small operations, and bundles of work are progressed down the production line througheach operation in sequence until the assembly process is compete.It requires large quantities of work in progressMost stable system- as it absorbs all imbalance because of the amount of work in progressMajor features of the system are;Supervision :- This system is not just involved in ensuring the correct movement of work  between sections, but is concerned with the movement and balance of work with in thesection.Labour:- This can be of various skill and cost levels because, the more complex theoperations are broken down into a series of small and relatively simple operations.Quality:- In-process quality control is now involved in inspecting individual componentrather than complete productProductivity:- productivity is higher than most of the other system, due to the breakdownof operations and possible introduction of specialized machines.Throughput Time:- This is considerably increased due to the amount of work stored atthe beginning and at the end of each section.Sept 2010 Intro to Indian Apparel Sector3

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