Productivity

Apparel Engineering (Ch.11), Production Planning and Management (Ch.12)

(Input) Materials

High efficiency Low-cost work Maximize productivity

(Output) Salable Garments

Productivity concept:
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ADM4307 Apparel Manufacturing By S. H. Shin, Ph.D.

Productivity is measured by achievement toward established goals based on relationship between inputs and outputs. The productivity and capability are measured with three things:
(1) Throughput Volume (The amount of work completed in a specific time), (2) Throughput Time (The amount of time it takes for a single unit of style to go through the production process, cutting to shipping) (3) Work in process (The number of garments that are under production at any given time).

Production Strategies & Workflow

Material handling

Production Strategies:
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FPP or CMT Production is market-driven (consumer demand)

Flexibility and fast throughput ( Quick Response) Strategies. Mass Customization (the most recent strategies).

Workflow:
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Workflow is the movement of materials and garment parts through the conversion processes. An inventory buffer to guarantee a smooth and consistent workflow and to avoid Bottleneck in process. Plant layout (see P. 335 figure 11-1):

Arrangement of departments, workstations, and equipments. Two types of plant layout:

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Line layout (product oriented layout) Operations are performed in a specified sequence. Less work in process, faster throughput time. Skill center layout (process oriented layout) Buildup of work in process More floor space.

Material handling: refers to the efficient movement of goods through the conversion process. p Just-In-Time (JIT) delivery is an operational strategy that coordinates arrival of goods with immediate use and minimal handing.

Apparel production systems

Apparel production systems

Progressive Bundle System (PBS):

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Unit Production System (UPS):

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Gets its name from the bundles of garment parts that are moved sequentially from operation to operation. 80% of apparel manufacturers used the bundle system.

Bundles Bundle tickets

A type of line layout that uses an overhead transporter system to move garment t components from workstation to workstation for assembly. Advantage: Reducing Direct/ Indirect labor costs Consider: UPS costs of buying and installation, training for system, and prevention of down time.

Apparel production systems

Production process and work study

Modular Production System:

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Production process:
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Modular production system is a contained, manageable work unit that includes an empowered work team team, equipment, equipment and work to be executed. Management and team training for empowerment (Team-based production system). Workflow in modular production

An operation breakdown is a sequential list of all the operations involved in cutting, sewing, and finishing a garment, component, or style. the analysis of the operations required to produce a style.

Work study:
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Work zone consists of a group of sequential operations (Toyota Sewing System, TSS).

Method analysis (Analysis of motion): Class 1~5 , see p. 351. Work measurement (to determine the time required to complete one element or one operation (Time study)
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Average observe time Standard Allowed Minutes (SAM) Allowance factor: a percentage of time added to the normal time to cover the short delays and interruptions in work.

Production planning and management (Ch. 12)

Production planning
Production Planning
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Production strategies: Mass customization

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Long term production planning:

Mass customization requires processing single orders with immediate turnaround. Th goal The l of f mass customization t i ti is i t to b be agile il enough so products can be made-to-order. (fully customized style, fit, fabric, and trim with delivery direct to home).

Based on forecasts merchandise plans, and budgets Based on customer orders

Short term production planning:

Production capacity p y( (output): p )

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Factors affect Output capacity

Space utilization and limitation Equipment type The size, skill, and productivity of the labor Product variation. Plant capacity Individual operation capacity Relationship of production standards to capacity (SAMs or SAHs) Managing plant capacity Learning curve application.

Example: Body scanning technology for custom fit.

Capacity

Example of relationships among capacity dimensions (see p. 368, figure 12-2) This will be in Exam!