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“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.
it increases team spirit which helps organization in improving work environment. Now let’s try to have a detailed comparison of Assembly line system to the Modular on ground realities. Assumed SAM-14.000 Manoj TiwariUser 2 .) 20 Cost/Month (Indian Rs.Assembly Line Vs. (For comparison and calculations the product taken is 5.000 Cost/Month (Indian Rs. experts’ comments and consultants’ views advocating the benefits of Modular manufacturing are available.0 min. Apart from above. which helps in quick response to style change with achieving quality standards.) for Modular System 120.Pocket Denim Jean. The Modular system enhances multi skill development of operators. Modular System “A comparison on reality grounds” A good amount of literature.) Rs.000 3000 -6000 40 Requirement for Modular System (Nos.)* Sewing Operator Iron man Quality Checker 3000 5000 1 7 1 -.) for Assembly Line 240. /Garment) Type of Salary/ Requirement Assembly Manpower Month for required (Indian Line (Nos. which provides Faster and efficient through put and better balancing of work by keeping lower WIP and needing less space. So first let’s have a crux of thatModular manufacturing is a type of Flexible manufacturing systems.* 3000 35.
there should be NO checkers. hence all these activities have to be done by the Sewing operator itself. shift/Day.000 *. SAM given is 14. *. Quality Check and Trimming activities.000 133.* -.0 = 1114 Units/ Shift Total Labor Productivity (Assembly Line) = 1114/63 = 17.As per the modular manufacturing philosophy.Salary figures are tentative.000 Total 63 22 331.0 Min. Considering 8 Hrs.times for Ironing. total available minutes/ shift will be 480. which includes.500 6000 20.65/14.0 Manoj TiwariUser 3 . Modular System “A comparison on reality grounds” Helper Trimmer Supervisor 2500 3000 10000 11 2 2 -.68 Units/Person/Shift Production calculation for Modular System – Expected Out put per shift @ 65% efficiency= (21X480)*0. Production calculation for Assembly Line So.* 1 27.65/14.Assembly Line Vs. helpers And Trimmers. manpower required for Assembly line will be= 50 Expected Out put per shift @ 65% efficiency= (50X480)*0.000 --10.0 Minutes. as per the above table.
000/ 30 = INR.Assembly Line Vs. but I suggest you to don’t go with this asMark Twain said.27 Units/Person/Shift Expenditure on wages/ Day (assuming Avg.331. Manoj TiwariUser 4 .4729 /Garment Gain / Garment by using Modular system over Assembly Line- INR. which may directly or indirectly affect this statistical figure.000 / 30 = INR.9039 / Garment Expenditure on wages/ Day (assuming Avg. Modular System “A comparison on reality grounds” = 468 Units/ Shift Total Labor Productivity (Modular System) = 468/22 = 21. 11033 /Day Cost / Garment for Assembly Line = 11033 / 1114 = INR.“There are three types of lies. 4433 /Day Cost / Garment for Modular System = 4433 / 468 = INR. damn Lies and STATISTICS” The same may happen here also.4309 / Garment Prima-facie opting Modular System over Assembly Lines seems a good deal. 0. 30 days in one month) for Modular System – 133. 30 days in one month) for Assembly Line . as we have not covered some crucial factors. 9.lies. 9.
Assembly Line Vs. we are using (unknowingly) 40 extra machines. Machine usage Vs. Idle Machine cost. by working with 8 Modules for a 5-Pocket jean . if we calculate straight. It means there are always some machines idle at any given point of time. Modular System “A comparison on reality grounds” These factors are1. hence 20% of the total machines are always kept idle. Machine usage Vs. by which you can successfully run an assembly line.One style having asymmetric Back). and it shows somewhere we are not properly utilizing the available costly resources. The another important point. Manoj TiwariUser 5 . so that the multiskilling can be utilized efficiently. Idle Machine cost 2. Keeping the sewing machine Idle is definitely a cost. we use 25 machines over 20 Sewing operators. Space Utilization 5. 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. incase there are small orders of different styles (For example.In a modular system machine to man ratio is always kept more than 1. Operator’s mentality Let’s discuss all above points one by one- 1. Consistency in Production/Day 4. Consistency in quality of the sewn product 3. Generally for a 5-pocket jean modular set-up.
which results in cost of poor quality. the production and productivity of that day for that module is in serious danger. once out put is done.Believing in the Modular manufacturing concept for garments. who is trained for 3 operations in absent. the quality of sewn product has to be ensured by the modular team itself. Consistency in daily production. Consistency in the Sewn Product quality level. and wrong parts attachment is very common problems).Assembly Line Vs. till the time you come to know about poor quality of the product. In this scenario when there is production pressure. 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. there is NO quality check as each operator is responsible for checking and rectification in the product if required). operator misses to check the quality (uncut threads. Manoj TiwariUser 6 . 2. a big loss of time. material and money has already been done. wrong sewing margins. 3. unmatched notches. there is provisions for audits only.Lets assume on a fine day 1 modular operator. As there is only final audit in modular system. Producing and making things wrong are bigger losses than less/no producing. Unfortunately if he is a crucial operator expert in Inseams or waist band attach.
who does only one operation and finding out a replacement for it. health issues and climatic calamities are very often. Space Utilization. Modular System “A comparison on reality grounds” In a country like India. will not be a big deal for you./Day ( against 468 Units/Day as calculated above @ 65% efficiency) and in the same conditions a line starts producing out put Avg. where festive seasons. the space consumed by 2 modules is equal to 1 Assembly line. Manoj TiwariUser 7 . 4. either use a multiskilled operator from somewhere else or use three different operators for these operations. It means from a space of 2 modules. till that time you have to compromise with daily avg. At the same time if this operator absence scene happens in assembly line. Apart from it. both the solutions are going to add extra cost to the process with no guarantee of achieving required quality level. we will get approximately avg. Here as a replacement you are left with two options.Pocket jean. which is equivalent to a space of a line. you have to deal with one and only one operator.In general practice for a 5. this scenario of key operator’s absent is very normal. whereas from a line you can get easily 1100 Units/Day. 1100 Units/Day(As calculated above) from 8th or 9th day of the line starts. 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.Assembly Line Vs. production of 250-300 Pcs . 500-600 Units/Day out put.
In both the cases. but as soon as he learns all this. OK.skilled takes a good amount of time. Space is definitely a big cost. it shows somewhere we are loosing space and not unable to get a logical out put from the given space.Assembly Line Vs. Now lets think about this concept of multi-skilling from operator’s mind set. the MANAGEMENT who invested so much time and everything in the operator training and multi-skilling is the LOOSER. Manoj TiwariUser 8 . he will learn more than one or two operations and will become a multi skilled operator. and the above results show better to have an assembly line over modules. 5. B. we need infect 4 modules (Equal to the space of 2 lines). 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. to get equivalent out put to an assembly line.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 operator’s training and making them multi. Operator’s mentality. he will leave this job and join another company who can pay him better. Modular System “A comparison on reality grounds” Hence its clear that. Multiskilling will put extra burden on him without giving no significant monitory benefits. resources in terms of money and manpower as well as managements patience also.
Assembly Line Vs.From above discussed points. Their success stories reveal the uniqueness and excellence right from automobile sector to apparels. There must be no compromise with fundamentals. it’s 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. there is nothing left all across the globe for modular systems to prove further. but the requirement is to run modules with discipline and religiously. Modular System “A comparison on reality grounds” These scenes don’t occur to such a scale while we are working with assembly line. Modular philosophy has its own advantages and benefits. Manoj TiwariUser 9 . No doubt. otherwise blind follow-up of modules may come up with bigger disasters. Conclusion.
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