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PRODUCTION TECHNOLOGY IN
GARMENT INDUSTRY
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PRODUCTION TECHNOLOGY
Factors
Supervision
Labour
Quality control
Productivity
Throughput time
Lay out
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PRODUCTION TECHNOLOGY
Types of production technology
Manual system
Mechanical transport systems
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PRODUCTION TECHNOLOGY
Manual system: Making through
Section or process system
Progressive bundle system
Straight-line or synchro system
Mechanical transport systems:
Selection conveyor belt system
Unit production system (UPS)
Quick response sewing system
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PRODUCTION TECHNOLOGY
Making through:
Traditional method of production (The entire
garment is made by one operator)
The labour required must be highly skilled and
versatile (exceedingly rare and increasingly
expensive) Large variety of garments have to be produced in
extremely small quantities
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PRODUCTION TECHNOLOGY
Making through: Characteristics
Supervision: not required
Labour: highly skilled
Quality control: is necessary
Productivity: low (lack of specialization)
Throughput time: reduced to minimum Layout: convenient arrangement of m/c
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PRODUCTION TECHNOLOGY
Section or process system:
Pre- assembling (preparation of small components
Eg: front, back, main assembly, lining making,
setting linings & finishing (B/H,B/S, etc)
Effective system for producing variety of styles in
reasonable quantities.
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PRODUCTION TECHNOLOGY
Section or process system:
Make
Small
parts
Make
backs
Make
fronts
Close
Backs
Andfronts
Set
collars
Andsleeves
Finish
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PRODUCTION TECHNOLOGY
Section or process system: Characteristics
Supervision: required more
Labour: varying levels of skill
Quality control: has to be very thorough
Productivity: some what higher than the above
Throughput time: longer due to larger WIP
Layout: planned according to the process flow
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PRODUCTION TECHNOLOGY
Progressive bundle system:
Various sections are according to the main
operation sequence, with layout according to the
sequence of operations required to produce aparticular component.
Work store is positioned at the start and end of
every section Due to buffer sections are independent
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PRODUCTION TECHNOLOGY
Progressive bundle system:
Make
pockets store
Finish
Prepare
fronts
Set
pocketsstore
Make backs store
Close
Back
And
front
store
Make
collarsstore
storeSet
sleeves
store
store
Setcollars
Make sleeves
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PRODUCTION TECHNOLOGY
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PRODUCTION TECHNOLOGY
Progressive bundle system:Characteristics Supervision: involved in ensuring the correct
movement and balance of work with in sections
Labour: various skill & cost levels
Quality control: in-process quality is now involvedin inspecting individual operation
Productivity: is relatively higher than that of mostof other systems
Throughput time: is considerably increased due toamount of work stored at beginning & end
Layout: is very important
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PRODUCTION TECHNOLOGY
Straight-line or synchro system
System is based on synchronized flow of work
through each stage of producing a garment.
Time synchronized is very important.
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PRODUCTION TECHNOLOGY
Straight-line or syncro system:
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PRODUCTION TECHNOLOGY
Straight-line or syncro system: Characteristics
Supervision: more concentration on line balancing
Labour: relatively high skill levels
Quality control: in-process inspection must be morealert and intensive
Productivity: all things being equal productivity levelscan be very high
Throughput time: very short as a result of thequantity of WIP
Layout: simplest layout straight line system
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PRODUCTION TECHNOLOGY
Mechanical transport systems
Selection conveyor belt system:
Reduces the handling of work to a minimum and
maintains the WIP at very low levels
Automatically feeding work containers to an
operator
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PRODUCTION TECHNOLOGY
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PRODUCTION TECHNOLOGY
Selection conveyor belt system:
Characteristics:
Supervision: feeding & spending more time with theoperator
Labour: all grades and all rates
Quality control: in-process systems are operated
Productivity: reasonably high
Throughput time: still measured in days because ofthe WIP
Layout: a very concept straight line
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PRODUCTION TECHNOLOGY
Unit production system (UPS):
No bundles
Garment components are automatically
transported from work station to work station asper pre-determine sequence
Time involved in pick up of work & its disposal is
reduced to the minimum possible Automatically recorded (computerized)
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PRODUCTION TECHNOLOGY
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PRODUCTION TECHNOLOGY
Unit production system (UPS):Characteristics
Supervision: feeding
Labour: all grades and all rates Quality control: in-process inspection stations are
built in line
Productivity: high
Throughput time: very short as a result of thequantity of WIP
Layout: any form suitable to the available area
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PRODUCTION TECHNOLOGY
Quick response sewing system (JIT)
Workstation is equipped with 2 to 4 m/c
All parts for one garment are loaded in to hanging
clamp attached to trolley (there should only be one
garment at each work station)
Workstations should be designed as per theconvince of the operator
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PRODUCTION TECHNOLOGY
Quick response sewing system (JIT)
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PRODUCTION TECHNOLOGY
Quick response sewing system (JIT):
Characteristics
Supervision: feeding
Labour: must be highly skilled
Quality control: in-process inspection stations arebuilt in line
Productivity: is very high
Throughput time: few garments result in extremelyshorter
Layout: A typical unit would have eight work stationarranged around the transport system
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PRODUCTION TECHNOLOGY
To sum up
There are materials movement systems to
suit every conceivable type of requirement
and the objective of them all is to reduce the
non-productive time involved in work
transport and handling at the work station
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Definition
Production: processes required to convert (inputs)
materials into completed products. (outputs) Production capacity: output capability of plant,
m/c, or work center in a given period of time.
Production planning: an integrative process of
coordinating plant resources with the demand Production system: an integration of material
handling, production processes, personnel, andequipment that directs work flow and generatesfinished products
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Work in process: the no. of garments under
production at any given time
Through put time: the amount of time it takes for a
style to go through the production process, cuttingthrough shipping.
Through put volume: The amount of work that can
be completed in a specific amount of time.
Effect of WIP on Through put time
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