An apparel production system is an integration of material handling, production processes, personnel and equipment that directs workflow and generates finished products. Three types of production systems commonly used to mass produce apparels are: * Progressive bundle system
* Unit production system
* Modular production system
Each system requires an appropriate management philosophy, material handling methods, floor layout and employee training. Firms may combine or adapt these systems to meet their specific production needs. Firms may use only one system, a combination of systems for one product line or different systems for different product lines in the same plant. Work Flow
Many parts of garment assemble is sequential, therefore, each operation is dependent on previous operation. This has significant implications in planning work flow and assembly. Work flow is the movement of material and garment parts through the conversion processes. It can be impacted by any part of a production process and constraint that develop. A slow operator, a machine that malfunctions, or flawed fabric may all be constraints to work flow. Balancing
Balancing is the process of planning a smooth work flow with a steady supply of work for each operation. Balancing invoves planning and scheduling input based on the demand for finished parts and products.
Operator’s cycle time
Lean defines cycle time as the time it takes to do a process. The other variations of the term: operator cycle times, machine cycle times, or automatic machine times NEED OF PROJECT
REVIW OF LITERATURE
Production planning is an integrative process of coordinating the demand for finished goods with available resources. Production planning may work many months ahead of planning delivery to ensure that specific materials, production capacity and reliable quality management are available when needed. * Long Term Production Planning:
Long term production planning(month or selling period) is based on forecasts, merchandise plans, and budgets. * Short Term Production Planning
For days or weeks is based on customer order.
Many parts of garment assembly are sequential; therefore, each operation is dependent on the previous operations. This has significant implementations in planning work flow and assembly. Work Flow is the movement of materials and garment parts through the conversion process. It can be impacted by any part of a production process and constraint that develop. A slow operator, a machine that malfunctions, or flawed fabric may all be constraints to work flow.
The production process involves myriad steps and depends on the talent and skill of many individuals. It is a team effort. Apparel making is not conductive precision mass production. Frequent style changes and varying degrees of fabric work ability force continual adjustment in the manufacturing process standardized equipment is difficult to design and implement and production is therefore dependent on skilled workers. An apparel production system is an integration of material handling, production processes, personnel and equipment that direct work flow and generates finished product. Three types of production systems that are commonly used to mass produce apparel or are: PROGRESSIVE BUNDLE SYSTEM
The progressive bundle system(PBS) gets its name from the bundles of garments parts that are moved sequentially from operation to operation. BUNDLES consists of garment parts needed to complete a specific operation or garment component for example an operation bundle for pocket setting might include shirt fronts and pockets that are to be attached. Bundle sizes may range from 2 to a 100 parts. Some firms operate with a standard bundle size while other firms vary bundle sizes according to cutting orders, fabric shading, size of pieces in the bundles, and the operation that has to be completed. Some...