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PRODUCTION TECHNOLOGY IN GARMENT INDUSTRY

PRODUCTION TECHNOLOGY
Factors
Supervision Labour Quality control Productivity Throughput time Lay out

PRODUCTION TECHNOLOGY
Types of production technology
Manual system Mechanical transport systems

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

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

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

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.

PRODUCTION TECHNOLOGY
Section or process system:

Make backs Make Small parts Make fronts Close Backs And fronts Set collars And sleeves

Finish

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

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 a particular component. Work store is positioned at the start and end of every section Due to buffer sections are independent

PRODUCTION TECHNOLOGY
Progressive bundle system:
Make pockets store Set pockets store Close Back And front Make collars store

Prepare fronts

Make backs

store

store

store Finish store Set sleeves store

Set collars

Make sleeves

PRODUCTION TECHNOLOGY

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 involved in inspecting individual operation Productivity: is relatively higher than that of most of other systems Throughput time: is considerably increased due to amount of work stored at beginning & end Layout: is very important

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.

PRODUCTION TECHNOLOGY
Straight-line or syncro system:

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 more alert and intensive Productivity: all things being equal productivity levels can be very high Throughput time: very short as a result of the quantity of WIP Layout: simplest layout straight line system

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

PRODUCTION TECHNOLOGY

PRODUCTION TECHNOLOGY
Selection conveyor belt system: Characteristics: Supervision: feeding & spending more time with the operator Labour: all grades and all rates Quality control: in-process systems are operated Productivity: reasonably high Throughput time: still measured in days because of the WIP Layout: a very concept straight line

PRODUCTION TECHNOLOGY
Unit production system (UPS): No bundles Garment components are automatically transported from work station to work station as per pre-determine sequence Time involved in pick up of work & its disposal is reduced to the minimum possible Automatically recorded (computerized)

PRODUCTION TECHNOLOGY

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 the quantity of WIP Layout: any form suitable to the available area

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 the convince of the operator

PRODUCTION TECHNOLOGY
Quick response sewing system (JIT)

PRODUCTION TECHNOLOGY
Quick response sewing system (JIT): Characteristics Supervision: feeding Labour: must be highly skilled Quality control: in-process inspection stations are built in line Productivity: is very high Throughput time: few garments result in extremely shorter Layout: A typical unit would have eight work station arranged around the transport system

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

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, and equipment that directs work flow and generates finished products

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, cutting through 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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