PRODUCTION SYSTEM

Progressive bundle unit system can be incorporated in the

manufacturing of t-shirts as handling of bundles of knit fabric will be
easy and as the over lock machines are quite faster than a SNLS
machine, handling them repetitively is easy rather than using all of
them one by one which may lead to the operators not getting
accustomed to the speed.

The progressive bundle system is a traditional production system

that has been widely used in the apparel industries for many decades
and still is today. In this system, bundles of garments parts are moved
in sequence from one sewing machine operator to the next. Each
worker receives a bundle of unfinished garments and performs a single
operation on each garment in the bundle. After finished of his/her work
on a bundle, they are re-tied the bundle and passed on to the next
operator. 

Features of a progressive bundle unit system

 Presence of center table.

 Pieces are fed either as single piece or as bundles.
 Material movement on table/tray

Advantages

 High productivity
 Reduction in training time and cost
 Semi-skilled man power can be used.
 Easy monitoring of individual performance.
WORKING STATIONS LAYOUT
In this layout, there are 9 workers employed to get maximum
efficiency. The workers doing the same job are placed facing each other
and closer. A center table is used as a temporary storage and to move
the pieces forward to the next operation. Here layout is done by the
sequence of 1,2,3,4,5,6,7. As the worker doing the same job are placed
facing each other or side by side, the materials are need not to pass a
long distance.

ERGONOMICS
The basic ergonomic principles to keep in mind while planning a
working condition are to have proper tools, to keep repetitive motion
to the minimum, to avoid awkward postures and to get proper rest.
Usually, stitching tasks which are sitting operations lead to pain in
shoulders, wrists and hands. Analysis reveals that 40% of the sewing
operators stoop forward >20 degree throughout the machine cycle and
60% tilt their heads forward >20% throughout the machine cycle. The
reasons for the above may be due to visual demands of the work,
geometry of the work station, and inadequate seating.

For sitting operation like sleeve hemming, the stools used by the
operators to sit are of major concern. Most of the industries lack
cushioning, back rests and height adjustability in their stools which may
lead to soreness in their neck, shoulder and reduce blood circulation to
their legs because they are supposed to sit for a long time.

Optimal ergonomics for sleeve hem operation

The chair should have back rest and the height should be
adjustable. The chair should be able to rotate. So, that the operator can
easily turn around. The back rest should be cushioned and should have
rounded edges that support worker’s lower back. The duration of
exposure to the work should also be maintained properly. Frequent
rest periods should be given. Proper cross ventilation through adequate
and properly placed windows should be present. Exhaust fans should
be present. The table height should be of elbow level. Proper lighting
should be there in there surrounding. The working area should be
provided adequately to the workers. the working area should be at
least of 0.5m*0.5m.