Sub: APPC Ranjan Kumar saha. Associate Professor. NIFT-Mumbai. ranjan777in@yahoo.

com, #9833663517
Apparel Manufacturing process: 1) Piece rate working system: Here a skilled operator performs the whole job and stitch a complete garment. This is not an advance method, and can be useful where and the order quantity is not high for a particular style and there is no consistency of the order. Disadvantage: It is comparatively expensive. The rate of production is not high.

2) Progress bundle system/ Progressive bundle unit: The progress bundle system (PBS) gets its name from the bundles of garment parts that are moved sequentially from operation to operation. This is most common method, and The 1993 Technical advisory committee report indicates that 80% of today¶s apparel manufacturers use the bundle system. Bundles are assembled in the cutting room where cut parts are matched up with corresponding parts and bundle tickets. For e.g. an operation bundle for pocket setting might include the shirt front and pockets to be attached. The no. of pcs. in a bundle can vary according to cutting orders, fabric shading and may vary from factory to factory. A bundle can contain 10 Pieces, a dozen or multiple of dozen.

Each bundle has a bundle ticket, which contains following informations, DateBuyerStyle No.Purchase Order No.Name of Pattern Part ± Size of the patternOperationNo. of pieces in the bundle ±

Operators retain a corresponding segment of the bundle coupon for each bundle they complete. At the end of a work day, bundle coupons are turned in and the earned time from

The progressive bundle system is driven by cost efficiency for individual operations.completed bundle tickets is totaled to determine the operator¶s compensation. difficult in controlling inventory. y y . Operators perform the same operation on a continuing basis. Small bundles allow faster through put unless there are bottlenecks and extensive waiting between operations. which allows them to increase their speed and productivity. *High rate of productivity. Due to large quantity of WIP (work in process produced) . This reduces paper work.absenteeism and equipment failure . for the improvement of method in progressive bundle system. This system may allow better utilization of specialized machine . may also cause major bottlenecks within the system.as the operator perform the same operation on a continuing basis. Disadvantage: *Operators work at different rates. facilities access to information and eliminates lost of bundle tickets. A progressive bundle system may require high volume of WIP(work in process) because of the number of units in the bundles and the large buffer of backup work that is needed to ensure a continuous work flow of all the operators. extra handling. and large inventory. this may lead to longer through put time. Bundles of the cut parts are transported to the sewing room where the assembly begins. KEY TO SUCCESS: The success of a bundle system may depend on how the system is set up and used in a plant. thus large quantities of work in process can build up ahead of some operations. Slow processing . poor quality concealed by bundles. The operator performs the same operation for all the pieces in the bundle and keep it aside until it is picked up and moved to the next operation. Firms may use electronic bundle tickets or smart cards at each work station along with their own identification card. Advantage: *The cost of production is low.

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