Production System is Mostly used in Garment Industry?

Garment Production Systems in the apparel industry refer to the methods and workflows used to produce garments, from raw materials to finished products. Different production systems are designed to optimize efficiency, reduce costs, and ensure quality, depending on the type of garment, production volume, and other factors. 

Here are the main garment production systems used in the industry:

1. Make Through System (Whole Garment Production System)

• Description: In this system, a single operator or a small group of operators completes an entire garment from start to finish.
• Advantages:
  • High level of quality control.
  • Flexibility in handling custom or small orders.
  • Operator satisfaction due to involvement in the full garment-making process.
• Disadvantages:
  • Lower productivity for mass production.
  • Requires highly skilled operators.
  • Time-consuming compared to other systems.

2. Progressive Bundle System (PBS)

• Description: This is one of the most traditional and widely used systems. Garments are assembled in a progressive manner, where each operator performs a specific task and passes the garment onto the next workstation.
• Advantages:
  • High efficiency for large volume production.
  • Easier to manage and control production flow.
  • Allows for specialization, as operators focus on specific tasks.
• Disadvantages:
  • Higher work-in-progress (WIP) inventory.
  • Risk of bottlenecks if one operator is slower.
  • Less flexibility in handling design changes or custom orders.

3. Unit Production System (UPS)

• Description: In this system, each garment unit is transported individually through the production line using an overhead conveyor system. The garments move automatically from one workstation to the next.
• Advantages:
  • Reduced handling and transportation time.
  • Real-time tracking of each garment’s progress.
  • Lower work-in-progress inventory.
• Disadvantages:
  • High initial investment in equipment.
  • Requires skilled operators and maintenance staff.
  • Less flexibility in case of breakdowns.

4. Modular Production System (MPS)

• Description: A modular production system organizes workers into small, self-managed teams or modules, where each team is responsible for producing a complete garment or a specific section of a garment.
• Advantages:
  • Increased flexibility and quicker response to design changes.
  • Improved quality control and faster problem-solving.
  • Higher worker satisfaction due to teamwork and variety in tasks.
• Disadvantages:
  • Requires highly skilled and cross-trained workers.
  • Complex to manage and requires strong leadership.
  • Potential for lower productivity in the initial stages.

5. Flexible Manufacturing System (FMS)

• Description: FMS allows for quick changes in production processes to accommodate different garment styles. It combines elements of modular and unit production systems with advanced technology to allow flexibility in handling small to medium production runs.
• Advantages:
  • High adaptability to changes in production volume and design.
  • Reduced lead times and increased production efficiency.
  • Better resource utilization.
• Disadvantages:
  • Requires significant investment in technology and training.
  • Complex to manage and operate.
  • Potential for inefficiencies if not properly implemented.

6. Lean Manufacturing System

• Description: Lean manufacturing focuses on minimizing waste and maximizing value in the production process. It involves continuous improvement (Kaizen), just-in-time (JIT) production, and other lean principles to streamline processes.
• Advantages:
  • Reduced waste and lower production costs.
  • Improved efficiency and faster production times.
  • Enhanced quality and customer satisfaction.
• Disadvantages:
  • Requires a cultural shift and commitment from all levels of the organization.
  • Can be difficult to implement in traditional manufacturing environments.
  • May require ongoing training and process adjustments.

7. Toyotism (Toyota Production System - TPS)

• Description: Developed by Toyota, this system focuses on eliminating waste, continuous improvement, and respect for workers. It uses concepts like JIT, Jidoka (automation with a human touch), and Kaizen to improve efficiency.
• Advantages:
  • Highly efficient with minimal waste.
  • Flexibility to respond to customer demand changes.
  • Strong emphasis on quality and continuous improvement.
• Disadvantages:
  • Complex to implement and maintain.
  • Requires significant training and a cultural shift within the organization.
  • Initial implementation costs can be high.

8. Combination Production System

• Description: This system combines elements of the various production systems to suit specific production needs. For example, a manufacturer might use a modular system for high-value, low-volume garments and a progressive bundle system for basic, high-volume garments.
• Advantages:
  • Flexibility to optimize production processes based on garment type.
  • Ability to switch between systems depending on order size and complexity.
  • Potential to achieve a balance between efficiency, cost, and quality.
• Disadvantages:
  • Complexity in managing different systems simultaneously.
  • Requires a high level of planning and coordination.
  • Potential for inconsistency in production outcomes.

Conclusion:

Selecting the right garment production system depends on various factors, including the type of garment, production volume, labor skills, and available technology. Often, a combination of systems may be employed to optimize production efficiency and meet market demands.