PRODUCTION

METHODOLOGY/SYSTEMS
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CONTENTS
1. INTRODUCTION
2. TYPES OF PRODUCTION
SYSTEMS
3. EVALUATION OF
PRODUCTION SYSTEMS
 1.
INTRODUCTION
Let’s start with the first set of slides

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 It is a system that depicts how the two-
dimensional fabric is transformed into a three-
dimensional garment in a manufacturing system.

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5 GARMENT MANUFACTURING SYSTEMS
The names of the production systems are based on the various factors like

▹ Utilization of several machines to assemble a garment,

▹ Layout of machines,
▹ Total number of operators involved to produce a garment and
▹ Number of pieces moving in a production line during the production of a
garment.

Garment industry could combine various production systems

6 FACTORS OF GARMENT PRODUCTION SYSTEM
Factors of garment production systems are
▹ Company affordability
▸ Equipment that are directly involved with workflow
▸ Machine or floor layout
▸ Management philosophy
▸ Materials handling system
▸ Personnel training
▸ Production processes

As the fashion industry evolved and demand for readymade garments is

increased, the need for mass production systems become the essential way to
meet the market demand.
 2.
TYPES OF PRODUCTION
SYSTEMS

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8 TYPES OF PRODUCTION SYSTEMS IN THE APPAREL INDUSTRY
There are three main types of apparel production system-

A. Production systems that are based on order quantity

B. Production systems that are based on customer nature
C. Production systems that includes on organizational choice
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Types of production systems that are based on order quantity:

▹ Individual production or make through system

▹ Progressive Bundle System / Batch production
▹ Mass production
10 INDIVIDUAL SYSTEM/MAKE THROUGH/WHOLE GARMENT SYSTEM.
▹ This is the traditional method of production whereby one operator assembles
the entire garment.
▹ Here a tailor performs nearly every operation required to make the garment,
including machining, hand work and pressing.
▹ In this production system the operator would be given a bundle of cut work
and would proceed to sew it according to his or her own method of work.
▹ The labor required by this system must be highly skilled and versatile, which
makes this system expensive.
▹ This system is effective when a very large variety of garments must be
produced in extremely small quantities.
▹ A typical application would be in the sewing room of a boutique, which
produces its own merchandise.
11 WHOLE GARMENT SYSTEM.
There are two types of Whole Garment Production Systems:

1. Complete whole garment.

2. Departmental whole garment.

12 COMPLETE WHOLE GARMENT.

▹ This type of system is used in few places, which are engaged in custom-whole
sale.

▹ They are normally high priced and exclusively made for a customer.

▹ They are limited in number and distribution; normally about 10–20 garments
are made.
13 DEPARTMENTAL WHOLE GARMENT
▹ The departmental whole garment system is also used by custom wholesale
manufacturers as well as high price or better dress manufacturers.
▹ In the departmental whole garment system one individual does all the work
with the equipment allocated to a department.
▹ For example on person does all the cutting work in cutting department, second
person does all the sewing work in sewing department, third person does the
pressing and packing work.
▹ The workers in this system may use more than one equipment to complete
his/her job.
14 ADVANTAGES OF WHOLE GARMENT
▹ More effective when a very large variety of garments in extremely small
quantities.

▹ To finish more pieces, to earn more money.

▹ Operator will be specialized in his own working area.

▹ The Work in Progress (WIP) is reduced, at a time one cut garment is given to
one operator and so the amount as inventory is reduced.
15 DISADVANTAGES WHOLE GARMENT SYSTEM.

▹ Highly skilled laborers are used, so the cost of labor is high.

▹ The operator is more concerned on the number of pieces finished rather than
the quality of work.

▹ Productivity is less due to lack of Multi - specialization.

▹ For long run/bulk quantity of same style is not effective in this system.
16 GROUP SYSTEM - SECTION OR PROCESS SYSTEM:
▹ This is a development of the individual system, with the difference that the
operators specialize in one major component and sew it from beginning to end.

▹ This is a very efficient system for producing a variety of styles in reasonable

quantities.

▹ For example, an operator specializing in backs would assemble the back and
yoke, label attaching, etc., and performs all the operations required to finish
that component.
17 ASSEMBLY LINE SYSTEM FOR APPAREL PRODUCTION:
▹ In this kind of garment production system, each operator is allocated to
carry out only one job/operation repeatedly.
▹ Some of the characteristics of this system are
The bundled cut garment pieces are moved successively from one job to
another job.
▹ One bundle comprises all cut components that are necessary to finish
the complete garment.
▹ Bundle tickets contain a master list of jobs for the garment style and
corresponding coupons for each job.
▹ A ticket number will be allotted to each bundle which represents style,
size and shade of the garment.
 BUNDLE SYSTEM AND PBS FOR GARMENTS
18 PRODUCTION:

▹ The bundle system, often referred to as the traditional garment

production system

▹ 80% of apparel manufacturers use Bundle system (PBS).

▹ The bundle system is a dedicated system comprising cut parts, tied into
bundles, to complete one or more sections of an apparel product.

▹ The bundle system enables manufacturers to gain economies of scale.

19 PBS Workflow
▹ Consists of garment parts needed to complete a specific operation or garment component.
▹ E.g. An Operation bundle for pocket setting might include shirt fronts & pockets to be
stitched together.
▹ Some firms operate with a standard bundle size, while other vary bundle sizes acc. to size
of pieces in bundle and operation to b completed.
▹ Bundles are assembled in the cutting room, where cut parts are matched up with
corresponding parts and bundle tickets.
▹ Workers (labour) transport and move Bundles of cut parts to sewing room via trollies.
▹ Operator scheduled to complete the operation and perform same operation on all pieces in
the bundle, retie the bundle, remove Bundle ticket and move bundle for next operation.
For example, the sleeve section could contain the following sequence of operations:
1. Run stitch collar
2. Collar turn/iron
3. Collar top stitch, etc
20 ADVANTAGES OF PBS

▹ Labor of all levels i.e. unskilled, skilled, semi-skilled labors are involved.
▹ Small simple operations.
▹ Quantity of each operation is checked during every single operation thus
quality is good.
▹ Due to bundle system, less chance of mixing up of parts…thus less
confusion.
▹ Bundle tracking is possible, so identifying and solving problems become
easy.
▹ Effective production control system and Quality control system
21 DISADVANTAGES OF PBS

▹ Time Consuming due to assembling, moving and un-tieing of bundles.

▹ More labor…More labor cost.
▹ Needs efficient supervising.
▹ Labor absenteeism can effect production due to incompletion of contracts.
▹ WIP is seen in large quantities in this production system, which leads to longer
lead times.
▹ Variety of styles and less quantity is not effective in this system.
▹ Proper planning is required for each style, each batch.
▹ Improper planning causes labour turnover, poor quality, less production, etc.
22 UNIT PRODUCTION SYSTEM (UPS)
23 UNIT PRODUCTION SYSTEM (UPS)

▹ A Unit Production System is a type of layout that uses an overhead transporter

system to move garment components from workstation to workstation for
assembly.
▹ It is mainly concerned with a single garment and not bundles.
▹ In UPS, there are hangers. One hanger have multiple clips containing all parts of
the single garment.
▹ All parts for the single garment are advanced through stitching line together by
means of hanging carrier that moves along an overhead conveyor.
▹ Hanging carrier can be moved manually by the operator using button after
completion of single operation or By computerized system that move the
conveyor after a specific fed throughput time
24 WORKFLOW OF UPS

▹ Load all the pieces of single garment in a product carrier.

▹ The product carrier with the pieces will be routed through the
different operation steps.

▹ At every machine/operation the patented chain will position the

product ideally.

▹ Completed the product arrives to an unloading station. The

empty product carrier returns to the loading station.
25 ADVANTAGES OF UPS

▹ The time involved in the pick-up and disposal is reduced to minimum.

▹ Output is automatically recorded, eliminates the operator to register

the work.

▹ The computerized system automatically balance the work between

stations.

▹ Improved lead times-less work in process.

▹ Improved space utilization (more machines can be adjusted)

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▹ Increased Productivity.

▹ Throughput time can be drastically reduced.

▹ Indirect labor costs are reduced (by elimination of bundle handling

and requiring fewer supervisors)

▹ Improved production and quality.

27 Disadvantages of UPS

▹Proper planning is required to be effective.

▹Highly expensive-buying equipment and cost of installing.

▹Specialized training for the system.

▹Planning needs to be effective every time.

▹UPS requires high investments where the payback period is long

 Evaluation of
production systems

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 The evaluation of garment production systems can be done by taking into
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consideration four primary factors such as

1. Processing time: It is the total working time of all the processes involved in
assembling a garment.

2. Transportation time: It is the total time consumed for movement of semi

finished or finished garments from one workstation or department to another.

3. Waiting time of unfinished garments: It is the idle time of a work bundle when
it waits for the next operation.

4. Inspection time: It is time taken for in-process inspection of semi finished

garments or final inspection of finished garments before packing.
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THANKS!
Any questions?