Monday, September 3, 2012

Progressive Bundle System of Apparel garments production

 of apparel garments manufacturing could be summarized :
There are so many popular apparel garments production systems, such as


-Progressive bundle system
-Unit Production System
-Modular Garments Production System
-Combined garments Production System

The progressive bundle system (PBS) of apparel garments production gets its name from the bundles of garment parts that are moved sequentially from operation to operation. This bundle system, often referred to as the traditional garments production system, has been widely used by garments manufacturers for several decades and still is today. The AAMA Technical Advisory Committee (1993) reported that 80 percent of the apparel manufacturers used the bundle system of garments production. They also predicted that use of bundle systems for garments production would decrease as firms seek more flexibility in their production systems.

Bundles system of apparel production consist 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 with garments. Bundle sizes may range from two to a hundred parts. Some firms operate with a standard bundle size of particular garments, while other firms 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 firms 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 corresponding parts and bundle tickets.

Bundles of cut parts are transported to the sewing room in the garments and given to the garments operator scheduled to complete the garments production operation. One garments 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 operation of garments production. A progressive bundle system of garments production 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 in garments.

The progressive bundle system of garments production may be used with a skill center or line layout depending on the order that bundles are advanced through garments production. Each style may have different processing requirements and thus different routing. Routing identifies the basic operations, sequence of garments production, and the skill centers where those garments operations are to be performed. Some garments operations are common to many styles, and at those operations, work may build up waiting to be processed.

Disadvantages of progressive bundle system of garments production:
The progressive bundle system of garments production is driven by cost efficiency for individual garments operations. Garments operators perform the same operation on a continuing basis, which allows them to increase their speed and productivity. Operators of garments who are compensated by piece rates become extremely efficient at one garments operation and may not be willing to learn a new garments operation because it reduces their efficiency and earnings. Individual operators that work in a progressive bundle system of garments production are independent of 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 of this type of garments production system. This may lead to longer throughput time, poor quality concealed by bundles of garments, large inventory, extra handling, and difficulty in controlling inventory of garments industry.

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