IDM
APPAREL PRODUCTION TECHNIQUES
2019 / 05
END TERM SUBMISSION
PROGRESSIVE BUNDLE SYSTEM
& UNIT PRODUCTION SYSTEM
SUBMITTED BY -
Jaswanth K P (MFM/20/317)
Ritaaksha Kumar (MFM/20/70)
Sri Pragathi (MFM/20/446)
Srihitha Sabbineni (MFM/20/52)
Under the guidance of
Ms. Shweta Jain
Submitted in partial fulfilment of the requirement for the degree of
Masters of Fashion Management Studies
2020-2022
CERTIFICATE
This is to certify that the Assignment Report entitled ” Production
Systems ” which is submitted by Jaswanth KP, Ritaaksha Kumar, Sri
Pragathi and Srihitha Sabineni in partial fulfilment of the requirement
for the award of degree Master of Fashion Management in National
Institute of Fashion Technology. The matter presented in this
Assignment is duly acknowledged and has not been submitted for the
fulfilment of any other degree.
Ms. Sweta Jain
(Project Supervisor)
Department of Fashion Technology (DFT)
National Institute of Fashion Technology (NIFT)
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ACKNOWLEDGMENT
It gives us great pleasure to present the Apparel Production Techniques
End term Assignment that has been undertaken during the NIFT MFM
second semester.
We would like to express our gratitude to all those who have helped and
guided us for the completion of this report throughout the working
period.
We are especially grateful to Ms. Swetha Jain for her suggestions and
support which helped us immensely in preparing this report. Without
his advice and support, it would not be possible for us to complete this
report.
Last but not the least we express our gratitude to all the individuals who
have helped us directly or indirectly
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TABLE OF CONTENTS
INTRODUCTION.........................................................................................5
PROGRESSIVE BUNDLING SYSTEM.................................................6
1. INTRODUCTION.................................................................................6
2. FEATURES............................................................................................7
3. ADVANTAGES.....................................................................................8
4. DISADVANTAGES..............................................................................9
UNIT PRODUCTION SYSTEM..............................................................10
1. INTRODUCTION.................................................................................10
2. FEATURES...........................................................................................12
3. ADVANTAGES....................................................................................13
4. DISADVANTAGES.............................................................................14
COMPARISON...........................................................................................15
CONCLUSION............................................................................................16
REFERENCES............................................................................................17
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INTRODUCTION
Production systems are needed to enable companies to produce the largest
number of products effectively and efficiently for the lowest cost but at the
required quality. It is an integration of materials handling, production
processes, personnel, and equipment that direct workflow and generate
finished products. Simply, it is a way how the fabric is being converted into a
garment in a manufacturing system. Garments can be made by applying
different types of systems. The garment production system used by an
individual or in small tailor shops is different when compared to the systems
used in the factories.
The types of the production systems are based on the various factors like
utilization of a number of machines to assemble a garment, layout of
machines, total number of operators involved to produce a garment and
number of pieces moving in a production line during the production of a
garment. The garment industry could combine various production systems to
achieve their specific garments’ production needs like utilizing only one
production system or a combination of different systems for one product
style. Designing the production system ensures the coordination of various
production activities. There is no particular production system that is
universally accepted, yet there are different types of production systems
followed by different organizations as discussed in the following section.
Any production system has four primary factors that make up the system.
Processing time is the sum total of working time of all operations involved
in manufacturing a garment.
Transportation time involves the time taken to transport semi finished or
finished garments from one department to another or from one
operation/machine to another.
Temporary storage time is the time during which the garment/bundle is
idle as it waits for the next operation or for completion of certain parts.
Inspection time is time taken for inspecting semi finished garments for
any defects during manufacturing or inspecting fully finished garments
before packing.
Processing time + Transportation time + Temporary storage time + Inspection
time = Total Production Time.
The different types of production systems are distinct and require different
conditions for working. However, they should meet the two basic objectives,
that is, to meet the specification of the final product and to be cost-effective
in nature. The main aim of any production system is to achieve a minimum
possible total production time. This automatically reduces in-process
inventory and its cost.
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PROGRESSIVE
BUNDLING SYSTEM
The progressive bundle system is a and so on. The success of PBS
traditional production system that depends on how the production
has been widely used in the apparel system is set up and used in a plant.
industries for many decades and In the cutting section cut
still is today. In this system bundles components of one style and in one
of garment parts are moved in size are clubbed and bundled using
sequence from one sewing machine ties. Bundle sizes could vary from 2
operator to the next. Each worker to 100 pieces according to the
receives a bundle of unfinished requirement of the production plant.
garments and performs a single Each bundle contains pieces of the
operation on each garment in the same style and same size only. A
bundle. After finishing his/her work ticket number will be allotted to
on a bundle, they are re-tied the each bundle which represents style,
bundle and passed on to the next size, shade of the garments and
operator. Each PBS task is given a number of cut pieces etc.
target time or “SAM” (Standard The bundles of cut parts are
Allowed Minutes). Time study transported to the sewing section
engineers calculate the SAM for an and given to the operators
entire garment for an experienced scheduled to finish the operation.
worker as the sum of the number of Thus bundles may be handled from
minutes required for each one sewing station to another in
operation in the production process, various forms such as tied bundles,
including allowances for worker bags, pocketed bags, bundle trucks,
fatigue, rest periods, personal time boxes and baskets etc.
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FEATURES Every operator receives the
bundle, performs their work,
This Progressive Bundle System is re-ties the bundle and passes
widely used in the garment it to the next operator.
industry who manufacture shirts, There is a storage facility such
jeans, jackets, etc. as rack, bin or table for storing
Sewing operations go in sequence. the inter-process work
Machines and operations are between each operation. The
organized in sections according to work is routed by means of
basic functions. tickets.
The requirement for machinery for Within each section, works are
each operation is determined balanced according to the
according to the output required. time required for each sub-
The garments are gradually function.
assembled in bundles as they
move through successive sub-
assembly and main assembly
operations.
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ADVANTAGES
Allows high productivity. Due to the bundle system, there
Utilizes a high level of labour and is less chance to mix-up, size
helps in reducing time and cost. and shade variation of cut
Uniform high quality of work can garment pieces.
be ensured by in-process control. Problems can be solved easily
Labourers of all levels (unskilled, since tracking of bundles is
skilled, semi-skilled labourers) possible here.
are involved in this system where An efficient production control
the operations are broken into system and quality control
simple operations. Hence the system could be implemented.
cost of labour is very cheap. Small bundles allow faster
Individual performances can be throughput unless there are
monitored and incentives are bottlenecks and extensive
offered. waiting between operations.
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DISADVANTAGES
The operators perform the Line balancing becomes difficult
same operation on a most of the time and this
continuing basis, which allows problem is solved by effective
them to increase their speed production supervisors and IE
and productivity but the Engineers.
operators who are Slow processing, absenteeism,
compensated by piece rates and equipment failure may also
become extremely efficient at cause major bottlenecks within
one piece operation and may the system.
not be willing to learn a new Large inventory, extra handling
style because it reduces their and difficulty in controlling
efficiency and earnings. So, inventory.
individuals working here are Inventory cost will be high due to
dependent on other operators higher Work in Progress in each.
and the final product. Proper planning is required for
Time-consuming due to each batch and for each style,
assembling, moving, tying and which takes a lot of time.
untying of bundles.
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UNIT PRODUCTION
SYSTEM
Unit Production system or UPS is flexible material handling system that
involves the requirement of a computerised overhead transportation system to
move the garment components automatically from one workstation to the
next according to a pre-determined sequence. It replaces the traditional
garment production system of handing, bundling, tying and untying, and
manually moving garment parts. It provides uninterrupted workflow to the
workers and helps in improving work efficiency and product quality. In the
fast-moving fashion and apparel industry, this is highly essential.
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UNIT PRODUCTION
SYSTEM METHODOLOGY
The working of this system comprises of
all the components for one garment that
are loaded into a carrier at a workstation
specifically designed for this purpose.
The carrier is divided into sections, with
each section having a quick-release
clamp, which prevents the components
from falling out during movement
through the system.
When a batch of garments have been
loaded into the carriers, they are fed
through a mechanical or electronic
device, which records the number of the
carriers and addresses it to its first
destination.
Some of the more intelligent systems address the carriers with all the
destinations they will have to pass through to completion. The loaded carriers
are then fed onto the main powered line, which continually circulates by the
small push of hand. This main line is connected to each workstation by
junctions, which open up automatically if the work on a carrier is addressed to
that particular station. The carrier is directed to the left side of the operator and
waits its turn along with the other carriers in the station. When the operator has
completed their work on one carrier, a push button at the side of the sewing
machine is pressed and this initiates a mechanism, which transports the carrier
back to the main line. As one carrier leaves the station, another is automatically
fed in to take its place. When the carrier leaves the station it is recorded on the
data collection system, and then addressed to its next destination.
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FEATURES This system is capable for rework
easily as each garment is tracked
within the system and any
This system is concerned with a problems with quality control can
single garment and not bundles, be traced back automatically to
for the ease of it the system is the operator to be corrected.
completely computerised. The system is highly flexible and
The layout design of this system can rapidly be modified to
can be U, L, J, S and E shaped. changes in the production line or
The workstations are constructed the need for expansion.
as close as possible to the It is possible to produce multiple
operator. So, the components are designs, colours and sizes at the
sewn without removing from the same time in the same production
hanger in most of the cases. line.
Up to 40 garment styles can be It can be widely used in garment
produced concurrently on this factories, especially for knitted,
system. woven, trousers, shirts and other
clothes.
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ADVANTAGES
Bundling, tying, untying and bundling and movement of garment
bundles is eliminated in UPS. These processes are highly time
consuming in the PBS and add little value to the finished product.
Ticketing is an essential process in the production bundling system
used for shade sorting, size labelling and counting garment
components. This process is eliminated in the unit production system.
UPS offers the advantage of real time data collection which helps in
planning production with minimal work stoppages and reduces
bottlenecks. This also helps in minimizing change in equipment and
color of the thread, to maintain a smooth workflow.
Labor costs are reduced as the operations involving the movement of
material within the line are eliminated. Some supervisor roles are also
eliminated when UPS is used.
UPS maintains a low work in progress inventory.
UPS helps in improving the machine and space utilization.
UPS reduces handling time of the fabric as some components in
garments can be sewn while the garment is suspended on the
conveyor belt in hanging position and also helps in keeping the
garment wrinkle free.
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DISADVANTAGES
Specialized training is required for the operators and supervisors
to operate the overhead conveyor system.
Unit Production systems are expensive in terms of cost of
equipment, installation and maintenance. It also takes longer to
get a return on investment, which places a financial strain on the
manufacturer.
Factories that run on more than one shift will have difficulty in
maintaining the downtime of the production system.
Efficient functioning of a Unit Production requires thorough and
meticulous planning in advance which is highly time consuming.
Unit production systems are not feasible for very frequent style
changes or garments with special requirements. It is best used
only with standard garments.
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COMPARISON
BETWEEN
PBS AND UPS
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CONCLUSION
As the fashion industry evolved and demand for readymade
garments are increased, the need for mass production systems
become the essential way to meet the market demand. Simply
because tailoring shops are not able to produce the volume and
supply across the world.
Through this assignment, we looked into two of the more
common production systems, Progressive Bundling System and
Unit Production System, wherein we evaluated the two based on
their functioning and advantages over the other. Even though
UPS can be seen as a better option in the garment industry, the
owner of an apparel manufacturing unit will buy these systems
depending on the production volume, product variety, and the
cost involved in buying and maintaining the machines for the
same.
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REFERENCES
https://textilestudycenter.com/progressive-bundle-system/le bit of body
text
https://www.onlinestudybook.com/unit-production-system-overhead-
production-system-hanger-production-system/
https://www.onlinestudybook.com/progressive-bundle-system/
http://textileaid.blogspot.com/2014/06/progressive-bundle-system-of-
garments.html
http://fibres2fabrics.blogspot.com/2012/09/progressive-bundle-system-
of-apparel.html
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