BY- ANU MAHTO PRIYANKA SINGH SAMIRAN HAZARIKA

In clump system ,a worker collects a clump of materials from the worktable and carries out the first operation. After he has completed his part of the work, he returns it to the table. A worker for the second operation then continues the work and so on.

The process is ' collection - work -return' continues until the whole garment has been assembled.
It has the same characteristics as the conventional bundle system

STORE

OPERATOR

With this system, sewing machines are arranged in lines. The work flows from the central (store) area to the first machine, from the first machine back to the store, and then on to the next machine, and so forth. A distributor stationed at the store is responsible for receiving and dispatching the work

In Clump system , product is manufactured section by section with the component units sewn together at end of manufacturing process. A clump bundle contains only a single part of the garment such as sleeve, body, cuff or collar. Etc. that means this system not only divide the work, but also divide up the garment. Machines of similar operations are clubbed together instead of spreading over in all lines. For example, when a mans formal shirt is being made in a section layout collars, cuffs and sleeves are in the preparatory sections and then send to the assembly section.

Specific quantity of parts in the bundle is determined by number of fabric plies and weight of bundle. Operators of specialized skills are independently working at own pace and paid by piece rates.

The system is flexible, as it can cope with frequent style changes.

Absenteeism and machine breakdown problems will not cause serious problems., as the controller can control the amount of work received and dispatched
The system is easy to operate and supervise. Specialization and rhythm of operation increase productivity. As the WIP is high in this system, this is stable system. It is easier to obtain a uniform level of quality, as the controller can check the quality control. The labor cost is less compared with individual system.

It requires excessive handling of the materials by the operators, as they have to carry their work back to the central inventory. Operators who are compensated by piece rates become extremely efficient at one operation and may not be willing to learn a new operation because it reduces their efficiency and earnings. It is difficult to control the inventory. It is difficult to see the work in progress at the various stages of manufacture. High level of WIP extends throughput time Engineering of work places is difficult because machines are arranged in the limited capacity. High level of work-in-progress. Large storage space is required to cope with the large volume of work-in-progress

The system is used in industries where there are frequent changes in garment style but a low level of managerial skill. This system is very efficient for producing a variety of styles in reasonable quantities. Orders in low to medium volume.

Difference from other manufacturing system

System attributes Clump system Work flow Method of retrieval to work station push Brought to operator or self retrieved by operator from store High level( racks or carts of bundles) Single task Production systems Progressive system push Brought to operator from operator by cart or conveyor Moderate level (enough to balance the lines) Single task No teamwork Modular system pull Hand off

WIP inventory

Zero to minimal

Number of task per operator

Multiple task Teamwork

Interaction No teamwork between operators

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