Abhishek Sharma V

Roll no BD/21/1543

APPAREL PRODUCTION
ASSIGNMENT 1[MID-TERM]

SUPPLY CHAIN OF
LEATHER GARMENT MANUFACTURER
 Directly to the consumers
Arrange tailors Garments order

Buying House
Agent
Tailors
Chemical manufacturer

Shipped to buying
Garments order
Chemicals used for

house
leather productions
Hide/skin

Distributed to retail stores

Leather

Slaughter
Tannery

Shipped directly to retail stores

machineries used for
leather garment
machineries used for Consumers

productions
leather productions Logistic agent

Garment manufacturer

Trimes as per ordered

Consumer buys from
retail

Trimes as per ordered

Lining
Machine manufacturer
Weaving industry
Fabric

Retail stores
Trimes

Trims manufacturer Trims wholesale

Textile manufacturer
distributor
 VARIOUS MANUFACTURING SYSTEMS
01 Make Through System
In the make-through system, a garment is sewn by a single operator in the traditional production method. The order of
operations is based on the operator's individual approach. This system demands a skilled and adaptable operator, a
combination that is becoming scarce and more costly.

Advantages: Disadvantages:

Ideal for producing a range of garments in very
small quantities
Operator works independently with minimal need
for managerial oversight
Low work-in-progress inventory
Ability to manufacture complex garments with ease
Skilled operators are essential, leading to high
labor costs.
Not ideal for producing large order quantities.
Operators are heavily relied upon.
 VARIOUS MANUFACTURING SYSTEMS
02 Progressive Bundle system
In a progressive bundle system, cut parts are bundled and loaded onto a sewing line. Each operator executes a single
operation and then hands the bundle to the next operator for the following step. This system is a method of assembly
where the bundle size is determined by the number of plies and the fabric shade during cutting.

Advantages: Disadvantages:

Low skill requirement so the cost of production is
low
Well-suited for mass manufacturing
Dependency on operators is less
Higher efficiency of production as operators
perform repetitive work
Production management demands significant
managerial oversight
Achieving line balance poses challenges
Ongoing training is essential to uphold skill levels.
The production line maintains a moderate Work-in-
Progress (WIP)
Possibility of bundle mismatch causing color
variation in garments
Bundling tasks (tying and untying) require time and
attention
 VARIOUS MANUFACTURING SYSTEMS
03 Unit Production System (UPS)
Unit Production system is a single piece flow system in which garment components are transported from one workstation
to other using automated systems in a pre-determined sequence. This system is also called overhead production system
because most automated systems are overhead systems.

Advantages: Disadvantages:

Handling time (pickup and dispose) is substantially Requires high Investment

reduced High managerial inputs and planning is required
No bundle handling The line needs to be balanced
Faster production lead time can be achieved Machine breakdowns can severely affect the
Minimum WIP production
Production is automatically registered as system is Outputs need to be always balanced as WIP is
automated minimum any problem in one operation affects all
The sewing line is clutter-free. other operations
Reduced handling and WIP leads to reduced
defects.
 VARIOUS MANUFACTURING SYSTEMS
04 Modular System
In modular manufacturing, operators do not sew the entire garment or focus on a single task. Instead, they handle a set of
operations collectively as a team. These operators are multiskilled, enabling each one to carry out multiple tasks, rotate
between workstations, sew, collaborate as a team, and distribute the workload evenly among themselves.

Advantages: Disadvantages:

Cost of production is less Multiskilled operators are required

Higher productivity as work is shared. More WIP is needed
Absenteeism and machine breakdown does not Quality control can be difficult
cause serious problems