production technology in garment industry01

7/27/2019 Production Technology in Garment Industry01

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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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Types of production technology

Manual system

Mechanical transport systems


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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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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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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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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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Section or process system:

Make

Small

parts

Make

backs

Make

fronts

Close

Backs

Andfronts

Set

collars

Andsleeves

Finish


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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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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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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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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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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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Straight-line or syncro system:


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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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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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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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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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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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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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Quick response sewing system (JIT)


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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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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

production technology in garment industry01

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