Progressive Bundle System of Garments Production | Traditional Garment Production System

The most common and traditional system of garment production is progressive bundle. Still now it has been used more than other systems.

This system of apparel  production is so called because the bundles of garment parts that are forward sequentially from one process to another. There need to complete a specific operation or component. For example neck join is a single process, through this kind of system an operator will join neck of full bundle then it will forward to another operator.


This kind of system has been called as its name from the bundles of garment parts that are moved sequentially from one to another operation. It is often referred to as the traditional process, has been widely used by the manufacturers for several decades and still in today. The American Apparel Manufacturers Association (AAMA) Technical Advisory Committee (1993) reported that 80 percent of the manufacturers use it. They also predicted that use of this type of system would decrease as firms seek more flexibility.


Bundle sizes may range from two to a hundred parts. Some industries operate with a standard bundle size of particular garments, whereas others vary bundle sizes according to cutting orders, fabric shading, size of the pieces in the bundle, and the operation that is to be completed. Some of them use a dozen or multiples of a dozen of garments because their sales are in dozens. Bundles of garments are assembled in the cutting room where cut parts are matched up with similar parts and bundle tickets.

Bundles of cut parts are transferred to the sewing section to concern operators and they are scheduled to complete the production. One operator is expected to perform the same operation on all the pieces in the bundle, retie the bundle, process coupon, and set it aside until it is picked up and moved to the next operator. In this process may require a high volume of work in process cause of the number of units in the bundles and the large buffer of backup that is needed to ensure a continuous work flow for all operators.

It might be used with a skill center or line layout depending on the order that bundles are advanced through production. Each style may have different processing requirements and thus different routing. Routing identifies the basic operations, sequences of  production, and the skill centers where those  operations are to be performed. Many of the operations are common to multiple styles in that case work may build up waiting to be processed.


Advantages of  progressive bundle system:
The of this system is of making may depend on how the production system is set up and used in a plant. It may allow better utilization of specialized machines, as output from one special purpose automated machine may be able to supply several operators for the next operation. Small bundles of fabrics allow faster throughout unless there are bottlenecks and extensive waiting between operations.

Disadvantages of progressive bundle system:
This processing type is driven by cost efficiency for individual operations. The operators perform the same operation on a continuing basis, which allows them to increase their speed and productivity but who are compensated by piece rates become extremely efficient at one piece operation and may not be willing to learn a new style because it reduces their efficiency and earnings. Individuals that work here  are dependent on other operators and the final product.

Slow processing, absenteeism, and equipment failure may also cause major bottlenecks within the system. Large quantities of work in process are often characteristic this may lead to longer throughput time, poor quality concealed by bundles of fabrics, large inventory, extra handling, and difficulty in controlling inventory of whole processing.
 

Progressive Bundle System of Garments Production | Traditional Garment Production System

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The most common and traditional system of garment production is progressive bundle. Still now it has been used more than other systems.

This system of apparel  production is so called because the bundles of garment parts that are forward sequentially from one process to another. There need to complete a specific operation or component. For example neck join is a single process, through this kind of system an operator will join neck of full bundle then it will forward to another operator.


This kind of system has been called as its name from the bundles of garment parts that are moved sequentially from one to another operation. It is often referred to as the traditional process, has been widely used by the manufacturers for several decades and still in today. The American Apparel Manufacturers Association (AAMA) Technical Advisory Committee (1993) reported that 80 percent of the manufacturers use it. They also predicted that use of this type of system would decrease as firms seek more flexibility.


Bundle sizes may range from two to a hundred parts. Some industries operate with a standard bundle size of particular garments, whereas others vary bundle sizes according to cutting orders, fabric shading, size of the pieces in the bundle, and the operation that is to be completed. Some of them use a dozen or multiples of a dozen of garments because their sales are in dozens. Bundles of garments are assembled in the cutting room where cut parts are matched up with similar parts and bundle tickets.

Bundles of cut parts are transferred to the sewing section to concern operators and they are scheduled to complete the production. One operator is expected to perform the same operation on all the pieces in the bundle, retie the bundle, process coupon, and set it aside until it is picked up and moved to the next operator. In this process may require a high volume of work in process cause of the number of units in the bundles and the large buffer of backup that is needed to ensure a continuous work flow for all operators.

It might be used with a skill center or line layout depending on the order that bundles are advanced through production. Each style may have different processing requirements and thus different routing. Routing identifies the basic operations, sequences of  production, and the skill centers where those  operations are to be performed. Many of the operations are common to multiple styles in that case work may build up waiting to be processed.


Advantages of  progressive bundle system:
The of this system is of making may depend on how the production system is set up and used in a plant. It may allow better utilization of specialized machines, as output from one special purpose automated machine may be able to supply several operators for the next operation. Small bundles of fabrics allow faster throughout unless there are bottlenecks and extensive waiting between operations.

Disadvantages of progressive bundle system:
This processing type is driven by cost efficiency for individual operations. The operators perform the same operation on a continuing basis, which allows them to increase their speed and productivity but who are compensated by piece rates become extremely efficient at one piece operation and may not be willing to learn a new style because it reduces their efficiency and earnings. Individuals that work here  are dependent on other operators and the final product.

Slow processing, absenteeism, and equipment failure may also cause major bottlenecks within the system. Large quantities of work in process are often characteristic this may lead to longer throughput time, poor quality concealed by bundles of fabrics, large inventory, extra handling, and difficulty in controlling inventory of whole processing.
 

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Garment Production Systems | Production Systems in a Typical Apparel Manufacturing Industry

From the process flow chart of textile processing we have already known garments making is the final stage of any textile material. This is the final stage where garments are being ready to wear by the customers. Garment making is the key objective of any textile processing so we can treat this as much valuable portion of textile production. It includes the production of finished cloths. This is an integration of materials handling, production processes, personnel, and equipment that directs work flow and generates finished goods.

The below mentioned types of systems commonly used for bulk production:

To get more successful result each and every system requires an appropriate management philosophy, materials handling methods, floor layout for spreading, , cutting & sewing,  and employee training. Firms may combine or adapt these systems to meet their desired quantity they need. Industries either use only one system or a combination of two or more for a single line, or different systems for different lines in the same unit.

Progressive Bundle System:

This system of apparel  production is so called because the bundles of garment parts that are forward sequentially from one process to another. There need to complete a specific operation or component. For example neck join is a single process, through this kind of system an operator will join neck of full bundle then it will forward to another operator.

Overhead or Unit Production System

This kind of system is a type of line feeding that uses an overhead transporter system to forward  parts from work station to work station for assembly. All the components for a single garment to be advanced through the production line together by means of a hanging carrier that travels along an overhead conveyor.

Modular Production System

It is a contained, manageable work unit that includes an empowered work team, equipment, and work to be executed. Modules frequently operate as mini-factories with teams responsible for group goals and self-management. The number of teams in a plant varies with the size and needs of the firm and product line in factories.

Make Through System
Through this system only one man can make a garment alone with doing all task to complete the whole process.It is frequently done in tailors where the tailor even makes pattern or use common patterns to cut fabric and does finishing of the garment. Single person of tailor shops do all jobs from cut to pack. In this system tailors are not depended to others.

Section Production System
This system is similar to the traditional progressive bundle system. But the difference is that, instead of one line, work is divided into multiple sections. Machines of similar operations are clubbed together instead of spreading over in all lines. For example, when a man’s formal shirt is being made in a section layout – collars, cuffs and sleeves are in the preparatory sections and then send to the assembly section. This system is popular to improve line balancing and utilization of human resources.

One Piece Flow System 

In this system an operator will responsible to make his operation as single garment basis and forward it to another operator. Instead of making a bundle of multiple pieces, bundle is made with all components of a single piece. Sewing machines in One-piece-flow system can be laid in a straight line or modular line. The key advantages of this system are less through put time, less WIP in the line.

Piece Rate Production System
This is one kind of  most popular production system in small and unorganized garment industries. Though people called it piece rate system, actually it is not a production system. Whatever Production system is used as mentioned above, when operators are paid according their works  that means how many pieces produced in an hour or a day, is named as piece rate system. Where workers gets value than traditional systems and will be paid day to day basis as well.

Combinations of Production Systems 

Factories may use first processing method for producing small parts combined with modular method. This reduces the investment in specialized equipment and reduces the team size needed. Industry consultants believe that a modular system combined with a unit system provides the most flexibility, fastest throughput, and most consistent quality. This would be particularly useful for large items such as overalls or heavy coats. The UPS would move the garment instead of the operators. Each manufacturer needs to determine what is best for specific styles.

Garment Production Systems | Production Systems in a Typical Apparel Manufacturing Industry

No comments

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From the process flow chart of textile processing we have already known garments making is the final stage of any textile material. This is the final stage where garments are being ready to wear by the customers. Garment making is the key objective of any textile processing so we can treat this as much valuable portion of textile production. It includes the production of finished cloths. This is an integration of materials handling, production processes, personnel, and equipment that directs work flow and generates finished goods.

The below mentioned types of systems commonly used for bulk production:

To get more successful result each and every system requires an appropriate management philosophy, materials handling methods, floor layout for spreading, , cutting & sewing,  and employee training. Firms may combine or adapt these systems to meet their desired quantity they need. Industries either use only one system or a combination of two or more for a single line, or different systems for different lines in the same unit.

Progressive Bundle System:

This system of apparel  production is so called because the bundles of garment parts that are forward sequentially from one process to another. There need to complete a specific operation or component. For example neck join is a single process, through this kind of system an operator will join neck of full bundle then it will forward to another operator.

Overhead or Unit Production System

This kind of system is a type of line feeding that uses an overhead transporter system to forward  parts from work station to work station for assembly. All the components for a single garment to be advanced through the production line together by means of a hanging carrier that travels along an overhead conveyor.

Modular Production System

It is a contained, manageable work unit that includes an empowered work team, equipment, and work to be executed. Modules frequently operate as mini-factories with teams responsible for group goals and self-management. The number of teams in a plant varies with the size and needs of the firm and product line in factories.

Make Through System
Through this system only one man can make a garment alone with doing all task to complete the whole process.It is frequently done in tailors where the tailor even makes pattern or use common patterns to cut fabric and does finishing of the garment. Single person of tailor shops do all jobs from cut to pack. In this system tailors are not depended to others.

Section Production System
This system is similar to the traditional progressive bundle system. But the difference is that, instead of one line, work is divided into multiple sections. Machines of similar operations are clubbed together instead of spreading over in all lines. For example, when a man’s formal shirt is being made in a section layout – collars, cuffs and sleeves are in the preparatory sections and then send to the assembly section. This system is popular to improve line balancing and utilization of human resources.

One Piece Flow System 

In this system an operator will responsible to make his operation as single garment basis and forward it to another operator. Instead of making a bundle of multiple pieces, bundle is made with all components of a single piece. Sewing machines in One-piece-flow system can be laid in a straight line or modular line. The key advantages of this system are less through put time, less WIP in the line.

Piece Rate Production System
This is one kind of  most popular production system in small and unorganized garment industries. Though people called it piece rate system, actually it is not a production system. Whatever Production system is used as mentioned above, when operators are paid according their works  that means how many pieces produced in an hour or a day, is named as piece rate system. Where workers gets value than traditional systems and will be paid day to day basis as well.

Combinations of Production Systems 

Factories may use first processing method for producing small parts combined with modular method. This reduces the investment in specialized equipment and reduces the team size needed. Industry consultants believe that a modular system combined with a unit system provides the most flexibility, fastest throughput, and most consistent quality. This would be particularly useful for large items such as overalls or heavy coats. The UPS would move the garment instead of the operators. Each manufacturer needs to determine what is best for specific styles.

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