Knitwear Production Planning (Slides text) Apparel Production System 1.

Apparel Production Systems an integration of materials handling, production processes, personnel, and equipment that directs work flow and generates finished products.

2. Apparel Production Systems an integration of materials handling, production processes, personnel, and equipment that directs work flow and generates finished products. Most of the production systems employed in garment factory are derived from Manual systems Mechanical systems 3 Apparel Production Systems an integration of materials handling, production processes, personnel, and equipment that directs work flow and generates finished products. Most of the production systems employed in garment factory are derived from Manual systems Manual system Section or Processes System Progressive Bundle System Straight-line or Synchro- system Apparel Production Systems an integration of materials handling, production processes, personnel, and equipment that directs work flow and generates finished products. Most of the production systems employed in garment factory are derived from

Manual systems Manual system Section or Processes System Apparel Production System

Oct 2011

Knitwear Production Planning Progressive Bundle System (PBS) Straight-line or Synchro- system

Mechanical systems Selective Conveyor Belt System Unit Production System (UPS) Quick Response Sewing System Modular Production Systems (MPS)

( Each production system has its own specific operational characteristics ) Manual system This is essentially traditional method of production the entire garment is assembled by one operator. specific operational characteristics are:Supervision Labour Quality control Productivity Trough put time Layout This type of system is effective when a very large variety of garment have to be produced in extremely small quantities. Exampe - sewing room of a boutique. Section or Processes System Operators specialize in one major component and sew it from beginning to end. The sewing room would have a number of sections, each containing versatile operators capable of performing all the operations required for a specific components. The sections are built according to the average garment produced, and includes; Operators specialize in one major component and sew it from beginning to end. Oct 2011 Apparel Production System

Knitwear Production Planning The sewing room would have a number of sections, each containing versatile operators capable of performing all the operations required for a specific components. The sections are built according to the average garment produced, and includes;

Pre-assembling (preparation of small parts) Front making Back making main-assembly (closing, setting collar and sleeves,..) Lining making Setting linings Finishing operation

specific operational characteristics are:Supervision Labour Quality control Productivity Trough put time Layout This is a very efficient system for producing a variety of styles in reasonable quantities. Progressive Bundle System (PBS) A traditionally employed in apparel production where the task of assembling the garment is broken down into small operations, and bundles of work are progressed down the production line through each operation in sequence until the assembly process is compete. It requires large quantities of work in progress Most stable system- as it absorbs all imbalance because of the amount of work in progress Straight-line or Synchro- system Based on synchronized flow of work through each stages of producing a garment. Time synchronization is the most important factor of this system because of the flow of work cannot be synchronized if work flow varies considerably wide. The manipulation required to balance the standard time may lead to illogical combination of operation. Oct 2011 Apparel Production System

Knitwear Production Planning

It is a very rigid system and particularly vulnerable to absenteeism and machine breakdown. Types:Chute System Bench System To be effective , the system requires Volume production Accurate line balancing Skilled supervisor Reserve operators Reserve machinery and equipment Selective Conveyor Belt System The system reduces the handling of work to a minimum and maintains the work in progress at very low levels. Automatic feeding of work containers to an operator and eliminating time consuming fetch and carry methods. A typical conveyor system Main conveyor Top belt Lower belt Unit Production System (UPS) An advanced apparel manufacturing system in which a single garment is progressed through a sequence of operations. Using a unit production system, a garment is automatically transported via a computer-controlled overhead hanging system. Which has been ergonomically designed to reduce the amount of handling of the garment. It is a single garment and not bundle is handled at a time The garment component are automatically transported on a pre determined sequence.

Oct 2011

Apparel Production System

Knitwear Production Planning The work stations are constructed as close as possible so the components are sewn without removing from system in most sequence Quick Response Sewing System For orders are small lot

Each station equipped with 4 / 5 machines Many operations are completed in that work station before it is transported to other.

Modular Production Systems (MPS) MPS is a contained , manageable work unit that imcludes an empowered work team, equipment, and work to be executed. Modules frequently operate as minifactoryies with teams responsible for group goals and self- management. The number of teams in a plant varies with the size and needs of the firm and product line. A factor contributing to the success of this type of operation is the flexibility of being able to produce a wide variety of products in small quantities.

Progressive Bundle System (PBS) The bundle system of garments part that are moved sequentially from operation to operation. This system is also referred to as the Traditional production system for several decades.

Oct 2011

Apparel Production System