“APPAREL

PRODUCTION
SYSTEM”
 Garment Production System
 In simple a ‘garment production system’ is a way how
fabric is being converted into garment in a
manufacturing system.
 The choice of best apparel production system depend
on the Product, The Policies of the Company and the
capacities of manpower.
 There are basically three Production systems:
I. Progressive Bundle System
II. Unit Production System
III. Modular Production System
1. Progressive Bundle System
(PBS)
 Also Called Material Handling System.
 As name implies the bundle of garment parts
move from operation to operation.
 Traditional Production system.
 Widely used by apparel manufacturers for
several decades and still today.
 80% apparel manufacturers use the Bundle
system (PBS).
 PBS Workflow
 Bundles consist of garment parts needed to complete a specific
operation (e.g. an operation bundle for pocket setting might
include shirt fronts and pockets to b stitched together.
 Some firms operate with a standard bundle size, while other vary
bundle sizes on to size of pieces in bundle and operation to be
completed.
 Bundles are assembled in the cutting room, where cut parts are
matched up with corresponding parts and bundle tickets.
 Workers (labor) 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.
Progressive Bundle System
 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.
 Dis-advantages of PBS

 Time Consuming due to assembling, moving and un-tying

of bundles.
 More labor…More labor cost.
 Needs efficient supervisor.
 Labor absentees can effect production due to
incompletion of contracts.
 Variety of styles and less quantity is not effective in this
system.
 Proper planning is required for each style, each batch.
 Improper planning causes labor turnover, poor quality,
less production, etc.
2. Unit Production System (UPS)
 A Unit Production System is a type of layout that uses
an overhead transporter system to move garment
components from work station to work station for
assembly.
 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.
 UPS Workflow

 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.
 Advantages of UPS

 Bundle Handling completely eliminated.

 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)
 Advantages of UPS (Cont.)

 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.
 Dis-advantages of UPS

 Unit Production system requires high

investment.
 Proper planning is required to be
effective.
 Highly expensive-buying equipment and
cost of installing.
 Specialized training for the system.
 3. Modular Production System/JTS

 A Modular Production System is a contained, manageable work

unit that includes an empowered work team, equipment and
work to be executed.
 The number of teams in a plant varies with the size and needs of
the firm and product line.
 Usually there are 4-15 labors in one team depending upon the
type of garment to be stitched and skills of labor.
 Teams may be used to perform all the operations (whole garment
production) or certain portion of assembly operations.
 Team is responsible for maintaining a smooth work flow, meeting
production goals, quality level.
 Modular Production System

 Team members develop an

interdependency to improve the process
and accomplish their goals.
 A worker in a team can perform Multiple
functions depending upon his skills (Multi-
skills).
Modular Production System
 Advantages of MPS

1) High Flexibility.
2) Fast throughput times.
3) Low wastages.
4) Reduced absenteeism.
5) Empowered employees.
6) Improved Quality.
 Dis-advantages of MPS

 A high capital investment in equipment.

 High investment in initial training.
 No compatibility between team members
can cause problems thus loss in
production…
 Dependency on the Team for whole
Production.
Thanks
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