YEAR 10

Manufacturing

GANTT CHARTS AND TIME PLANS

A Gantt Chart shows:Overall timeline for a projectThe separate stages/tasks that need to be completedTime allocation for each taskThe order of work

In industry, time plans like this must be accurate as they are used to calculate:

•The overall cost of the product

•The cost of each process used to make and finish the product

•How long it will take to complete a customer order

Manufacturing Specification

A manufacturing specification (production plan) must provide a clear set of instructions and diagrams to enable the manufacturer to make the product exactly as the designer envisaged.

IT IS IMPORTANT THAT IT INCLUDES:A time line and plan for each stage of manufactureDetails of necessary quality control checks

Control Checks

Quality control checks take place:

•In fabric storage

•In the splitting phases

•In the packing area, warehouse and dispatch

•After each fusing and sewing phase

•In the finishing, inspection and packing areas

Quality Control ChecksDetails of quality control checks should include:

When the check is to take place.

What is to be checked.

How it is to be checked.

What the tolerances are.

A TOLERANCE is a range of acceptable measurements. Anything outside of this range is classed as faulty.

For example, a seam may need to be 3mm from the edge of a pocket but, if there is a tolerance of +/- 1mm, any seam between 2mm and 4 mm from the edge is acceptable.

Computer Systems In industry, the key advantages of using computers are that they:

Provide an effective means of presentation

Reduce the time taken to create products

Improve communication

Reduce repetitive work

Decrease costs and increase efficiency

Examples of computer systems used in the textile industry include:

Computer Aided Administration (CAA) – computers are used for marketing, sales order processing and stock control.

Computer Aided Design (CAD) – computers are used for developing designs, pattern making, pattern grading, marker production and lay planning.

Computer Aided Manufacture (CAM) – computers are used for store design, lay planning and cutting, sewing and pressing.

Computer Integrated Manufacture (CIM) – a system that uses computers at every stage of planning, design and manufacture.

Electronic Point-of-Sale (EPOS) – a computerised system that speeds up sales transactions and monitors stock levels.

New Technology

Many companies take advantage of new technologies, such as:

Skype, instant messaging, video conferencing, blogging, E-retail, interactive design, networking sites, virtual imaging.

Virtual imaging can be used to show what a design will look like before it’s manufactured, for example:

•Fashion designers may use softwear like 3D Runway Designer to display their designs on virtual models

•Interior designers may use mapping softwear or specialist programs to create virtual interiors.

LOOK AT THE WEBSITE: www.optitex.com

Examples of How ICT is Used (1)

The next two slides show how computers and other pieces of digital equipment may be used at various stages of design and manufacture.

Examples of How ICT is Used (2)

The Three Phases

PRE-PRODUCTION•Research ideas on line.•Present ideas using mood boards developed in specialist graphics packages.•Develop initial designs using vector drawing graphics software.•Design fabric range using specialised CAD graphics software.•Model fabric on product using 3D Image Draping system.•Garment specification created.

There are 3 phases to the creation of a commercial textiles product. ICT is used in all of them:Pre-production (the design phase).Production.Post-production.

POST-PRODUCTION•Sales and Marketing Department use a virtual design system, which shows how the product can be displayed on in-store systems.•To launch the product it can be placed on the web and a virtual fashion show can take place.•Product is sent to retail outlet where it can be tracked with EPOS (a computerised barcode system).•On-line retailing.

PRODUCTION PHASE•Product testing on all relevant parts.•3D image can be generated via a flat 2D pattern and mapped on a computer model called an ‘avatar’.•Costings are generated using PDM (Product Data Management) software and Manufacturing Specifications.•PDM systems are used for tracking materials and components for the product before the manufacture starts.•Product specification is used with specialist software for pattern making.•A lay-plan is created, using software which calculates the best way of laying all the pattern pieces on the fabrics to minimise wastage.•Fabrics are cut out using a specialised cutting table.•Production sample is made.•Product sent to production line (which may be in a manufacturing plant abroad).•Product is made.

The Three Phases (continued)...

The 4 main types of production system are:

•Haute Couture

•Individual/job production

•Batch production

•Mass production

The system used depends on the:

Type of product

Number of products to be made

Number of components and processes used

Quality required for each delivery

Production Systems

‘Off-the-Peg’ Manufacture

Just-in-Time Stock Control

Just in time stock management means that materials, components and sub-assemblies are delivered a short time before they are needed. This means that:

•Less space is required for storage.

•No money is wasted on surplus stock.

With this type of stock control there must be no mistakes, otherwise production can be held up.

Except for the Haute Couture and individual/job production, the different production systems are designed to produce ‘off-the-peg’ garments (ready made garments in standard sizes).

Using templates in standard sizes helps to keep costs down.

One-off garments that are made to specific measurements for an individual are called ‘bespoke’ and are usually far more expensive.

Other Production Systems

CELL PRODUCTION OR SECTION SYSTEMS...Divide the workforce into small teams that all produce the same productRely on each team to take responsibility for the quality of the products produced by them

PROGRESSIVE BUNDLE PRODUCTION...Uses small teams that are each responsible for a particular part of the production processIs like cell production, but for individual parts of the garment