Modular Production System |

Cellular Garment
Manufacturing | Toyota
Sewing System

Modular Production System

Modular production system involves a group of 4-17 people who set their own
standards and work together to produce a finished garment. They work as a team or
module and each team member works on more than one operation. In this system,
operators help each other to finish the garment quickly and the team is fully
responsible for the production and quality. The number of teams in a plant varies
with the need of the industry, size of the industry and product line in garments.
This system MPS is the perfect solution for the apparel manufacturer where quick
response is needed. This system is also popular as a Cellular Garment
Manufacturing, flexible workgroups or Toyota Sewing System (TSS).
Features of a Modular Production System

 Usually, U-shaped layout with more workplaces than operators.

 Required multiskilled workers and a small set of machines to produce a

finished garment.

 Each operator performs approximately 2-4 operations, depending on the

product.

 Workflow is sequential.

 WIP is less and productivity is high in this production system

 The operators stand /sit at their stations and rotate in different sewing
machines to complete the operations.

 Pull-type production systems, in which the job order arrives from the last
step to previous steps

Advantages and Disadvantages of Modular Production System

Advantages

 MPS leads to cost savings.

 The system is highly flexible with style changes and permits better line
balancing.

 Enables fast throughput time, lower WIP, and small batch size can be
achieved.

 Peer pressure encourages a team spirit and discourages absenteeism.

 Productivity of human labor

 Reducing supplies of unfinished production

 Required less floor space

 Improved quality of the product

Disadvantages

 This system requires a higher degree of communication and cooperation

among operators, mechanics, and supervisors.
  High capital investment is needed in initial training workers to deal with
several tasks at one station.

 Operators cannot develop the rhythm and pace of high performance.

 No harmony between team members can cause problems, thus loss in

production.

 Depend on the Team for whole Production.

Applications

 Fashioned garments with quick response.

 Orders with low volume and frequent changes.

 Company with mutual trust between management and operators.