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Hafsa Azhar Tmm-4 15 th Dec, 2011
What is Unit Production System(UPS)?
Its Invention-Eton Mechanics Traditional Production Systems Comparison between PBS,MPS AND UPS Advantages and Disadvantages How successful is Unit Production System Conclusion References
production processes.Production Systems An integration of material handling. personnel. and equipment that directs work flow and generates finished products. it also depends on the volume of production. . Several types of production systems are available and the product characteristic is highly related to the type of production system. The best apparel production will depend on the mission and policies of the manufacturing firm as well as the capacities of the personnel engaged in the production departments.
Production Systems .
Unit Production System .Production Systems Figure 1. Progressive Bundling System Figure 2. Modular Production System Figure 3.
. a garment is moved automatically through the overhead hanging system which is controlled by the computer. It enhances the productivity and guarantees a premium workflow.What is Unit Production System (UPS)? In an unit production system. It is designed ergonomically to minimize handling and manual transportation.
Types of UPS There are two types of UPS. Unit Production System Manual Unit System Automatic Unit System .
MANUAL UNIT PRODUCTION SYSTEM In Manual UPS labor uses hand to move conveyers to the next station when one operation is completed. In manual UPS we can skip any machine by changing the main track of conveyers. in the same way all the conveyers lines passes through all sewing machines.1. . Its structure is like railway lines which passes through all railway stations.
When operator completes his work than he press the button on the side of sewing machine. . Data collection system recorded the data each time when carries leaves the station. The carriers is divided into section having quickrelease clamp on each. which records the numbers of the carrier and addresses it to its first destination. When a batch of garment has been loaded into carriers they are fed past a electronic device. which continually circulates b/w rows and is connected to each workstations by junctions.2-AUTOMATIC UNIT PRODUCTION SYSTEM All the components for one garment are loaded into a carrier at a workstation. These carriers are then fed onto the main powered line. which directed carrier to the main line.
. Lead times were too high causing: Demands for quicker delivery times that could not be met. the Swedish apparel industry was experiencing a number of cost related problems. These above factor caused the Eton Shirt Company to address these inefficient material-handling procedures. Garment workers were forced to waste time in handling and transporting material. Technological advances.What Happened …. Changes in industry as a whole. Higher wages . Capital was needlessly tied up in work-in-progress.?? In the mid 1960s.
but production could now be planned and controlled down to the finest detail. self-trained technician and co- owner of the Eton Shirt Factory. He designed a creative hanging conveyor system that didn't waste valuable floor space and required no major modification to existing machines. The factory’s efficiency increased immediately.EUREKA….. . effective. Inge Davidson. It was simple. Not only did productivity improve. and brilliant.
Work Stations Head Rail Electronic Line Control(ELC) Quality Control and unloading . 4. which makes it very easy to adjust for every customer's specific needs.The mechanics of Eton System (UPS) The Eton system is a computerized overhead conveyer with workstations. 5. 3. Loading Station 2. The system eliminates manual transportation between workplaces as well as non-productive operator time. It is built from modules. It Consist of five main working processes: 1.
LOADING STATION .
Work Station .
Head Rail .
Electronic Line Controller .
QC & Unloading .
Sometimes. as production managers are unable to manage or plan the production effectively. This system. often referred to as the traditional garments production system. the operators have to stop and leave their workspace to look for the bundles. . This is an INEFFECTIVE practice. but still several decades and still is today This method requires bundle to be transported to individual sewing operators. factory porters/helpers are hired to do this transporting work.Traditional Methods Progressive Bundle Handling(PBS) Gets its name from the bundles of garment parts that are moved sequentially from operation to operation. But usually.
. 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 in garments and so the success of this type of garments operation is in the flexibility of being able to produce a wide variety of products in small quantities in garments. manageable work unit that includes an empowered work team. costs and need for specialized machinery. The overall objective is to provide a production methodology which will enable entire production system to be rapidly designed and configured for a wide range of consumer products with minimal delay.Traditional Methods Modular Production System A modular production system is a contained.
Comparison between PBS and UPS .
-Easier pick up and dispose at each work station. Unit production System Transportation -In this system an automated mechanical system carries pieces to each work stations. -Operators stop their work to fetch bundles. A balanced flow of material established in between cutting and sewing line.Parameters Progressive Bundle Handling Manual transportation. Resulted quick response time -Less effective in terms of production management. Lower WIP results in less cutting works. cutting sections are required to perform 60-70% more than actual production can handle. Resulted long response time. Cutting Work As a result of High Work In Process (WIP) is required by sewing section. many times helper are hired for this bundle transportation job. .
As workstation has limit of holding no. of hangers. This resulted piling up of work in the operations with higher work content.fabrics and trim has to be stocked before hand Less inventory for fabric n trims . so less handling of garment components. Direct labor content is less than PBS because an operator only sews the garment part rather than other tasks. positioning components. of bundles kept in between two operators. But it is not the minimum time as in this system there is WIP in between two operators. Less WIP in between operators. Work In process(WIP) In PBS generally operators are asked to sew as much pieces as they can without considering back and front operators. Direct labor Content Direct labor content is high because usually operator does tying and untying of bundles. In this system garment parts are held by the over head hanger. Also after completion of operation hangers are transported to the next operation automatically. pulling the bundle ticket and handling of work pieces. Inventory Level Due to high WIP and cutting . Through put time in UPS is less compare to PBS. How much long will depend on the bundle size and no. through put time longer in PBS.Parameter Progressive Bundle System Unit production System Through-put Time Compare to UPS.
Quality is improved Labor cost is reduces by elimination of bundle handling Less rejection Automatic counting Increase productivity Easy shifting of panels through each operation All the activity data can be easily transferred to the companies Management Information System .Advantages Through-put time is reduced as the work in process levels are minimized.
Disadvantages Huge amount of cost is required in installing the UPS Specialized and skilled training system and employees required Hard to make small parts such as loops. zipper and pockets .
Success… Let see…how successful UPS it is through out the world. .
The system provide the apparel units to utilize their existing recourses in a much better way. .Conclusion In today's ever changing market conditions. solving problem before they occur. UPS is a system that you can rely on. identifying bottleneck signs and reading visual clues to take immediate action. It provides ergonomic benefits that directly translate less fatigued operators and improved productivity. This system helps the production line to work proactively. making comparative analysis.
iigm.html http://www.html .se/oldsite/CompanyFacts/AboutUs.h tml http://www.in/pt_e_es.html http://www.html http://fibres2fabrics.References http://www.com/worldtextile/Textile-ApparelApparel/Progressive-Bundle-System-1-128948.html http://forum4.com/2011/02/comparisonbetween-progressive-bundle.iigm. pdf http://www.in/pt_e_wt.in/pt_eton.onlineclothingstudy.iigm.com/2011/05/apparelgarments-production-systems.eton.se/oldsite/TheEtonSystem/Articles/TC2.blogspot.aimoo.eton.html http://www.
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