Apparel management & quality control

Types of production processes Progressive Bundle System Modular Production System Unit Production System

Progressive Bundle System (PBS) The Progressive Bundle System the bundles of garment parts are moved in a sequence from one operation to another. The operators specialize in one major component and sew it from beginning to end. The garments are gradually assembled as they move through successive sub-assembly and main assembly operations in bundle form. This system, often referred to as the traditional production system.

Modular Production System (MPS) This system focuses on a team method of assembly. The members of a team are responsible for either the entire garment or a specific operation of the assembly process, depending on the overall production plant and the number of components to be put together. MPS is efficient garment assembly system as it reduces production time and improves quality. Since workers get to do different tasks, there is cut down on work monotony and job performance is enhanced.

Unit Production System (upS) It is a type of assembly line layout that uses an overhead transportation system to move garment components from one work station to another for assembling the garment. All the parts for a single garment are moved forward through the production line by means of a hanging carrier that travels along an overhead conveyor.

Material Handling Systems Used in the Garment Industry Material handling system plays an important role in improved material flow and increasing production performance in the readymade garment industry. If you ever visited a garment factory, you might have seen various kind of material handling equipment used by them. In this post I’ll be discussing different types of material handling systems found in the readymade garment industry.

Material handling system- Definition The means used for transporting work (like fabrics, cuttings, bundles, finished garments and general items) from one place to another, storing materials and protecting material from damage, are called material handling system. It may be an equipment, device or procedures. For better material handling, equipment are engineered according work place design

Material handling equipment for cutting department Cutting department is responsible for cutting garment patterns/component from the fabric rolls. Cutting department has to handle lot of fabrics and cutting bundles. So they need material handling tool and equipment like these. Trolleys: For transporting fabric from fabric store to cutting section. Forklifts are also used for this purpose. Baker's trolley: For stacking cuttings and transporting cutting bundles to stitching floor Plastic trays and trolleys: Cut pieces are placed on treys. Trays filled with garment with certain number of pieces are placed in trolley. Fabric Bags: Cuttings are bagged into fabric bags or plastic bag and carried out to production section manually. Racks: Racks used for storing cutting bundles (WIP). 

Material handling equipment for stitching department Garment stitching department does stitching of garments from fabric (cuttings). Different types of line layout for stitching line are found in the garment industry. Based on the production line layout, material handling system is designed. In stitching department material handling system is needed for transporting bundles from one workstation to next workstation, and for storing WIP.  Conventional side table (with bin): A side bench or a side table is placed for loading cuttings and disposing stitched garments. This kind of layout is normally found in group production system and make-through production system. Centre table: Centre table is the most common material handling system used in the production line (progressive bundle system and single piece production system). A bench (2-1.5 ft wide) is placed in between two rows of machines. See following images.

Material handling equipment for stitching department 

Trolleys: Cutting bundles are stacked on trolley and the trolley is moved in the line. Some factories found it difficult to assess WIP in the line by using trolley system. These trolleys are useful for trouser manufacturing. See image

Plastic crates and Bins: Bins are used for disposing stitched garments Plastic crates and Bins: Bins are used for disposing stitched garments. Plastic bins are used for transporting garments from one place to another.  Overhead production system (unit production system): Many production units use overhead rail and hanger for transporting material. Factories found it is easy to track WIP on the UPS system. Some factories experience issue in line balancing. Different types of overhead hanger system are available. Example of manual hanger system and computerized hanger systems are shown in following images. Manual hanger system:

Semiautomatic hanger system: Computerized hanger system:

Material handling equipment for finishing department: In the finishing department, garments are pressed, checked, folded and packed. In finishing section garment pieces move number of workstations before pieces are packed into the polybag. Common material handling equipment found in the finishing section includes -  Trolleys: Transporting garments from one workstation to another workstation. 

Bench: Used for stacking pressed garments Hangers and stand: Sometimes garments are not folded and shipped in full length in hangers. Pressed garments are hanged on hangers and stored in a stand.  

Quality- Definition The totality of features and characteristics of a product that bear on its ability to satisfy stated or implied needs. Quality can also mean meeting customer`s expectations, while maintaining a cost competitive market position.

Costs of Quality In context to garment industry, quality costs can be divided in to following four areas: Prevention Cost Appraisal Cost Internal Failure Cost External Failure Cost

Prevention Cost Prevention cost includes the cost of planning various quality functions, cost of evaluating prototype samples (whether testing or wear trial or both), cost of writing specification, cost of personnel performing such activities.

Appraisal Cost Appraisal cost includes inspection costs, testing costs, personnel costs associated with inspection and testing. Testing costs would include cost of the samples destroyed in testing, laboratory supplies etc.

Internal Failure Cost Internal Failure cost includes repair cost, scrap cost, cost of re inspection, personnel cost associated with these activities.

External Failure Cost External Failure cost includes cost of returned merchandise, cost of claims, cost of transportation for the defective merchandise and personnel cost associated with these activities.