Apparel Production Management

Group 2- Aastha Battu (MFM/20/42) Assignment 2-Modular

Agnija Barick (MFM/20/112)
Ananya Agarwal (MFM/20/46) Production System
Akansha Pandey (MD/19/86)
Submitted to-Ms. Shweta Jain

National Institute of Fashion Technology, Bengaluru

 Table of Contents
Introduction to
Advantages &
01 Garment Production
System
05 Disadvantages

Introduction to
02 Modular Production 06 Comparison
System

03 Features and
Applications
07 Conclusion

04 Process 08 References

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 01

Introduction to
Garment
Production
Systems

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 Garment Production System

● Simple terms - The way in

which fabric is being
converted into garment in a
manufacturing system
● The choice of best apparel
production system depend on
the Product

Image Source: https://www.academia.edu/44082242/Modular_Garments_Production_System

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 Characteristics

● Production systems are needed to enable

companies to produce the largest number of
products
● Garments production system is an
integration of materials handling, production
processes, personnel, and equipment’s that
direct workflow and generate finished
products. Image Source: https://apparelresources.com/business-
news/manufacturing/make-through-sewing-system-i/
● Basically three production systems -
Progressive Bundle System, Unit Production
System and Modular Production System 5
 Modular
Production
System

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 Introduction to Modular Production System,
Cellular Garment Manufacturing,Flexible work groups or Toyota
Sewing System
● Modules are defined as physical structures that have a one-to-one correspondence with
functional structures.

● A modular production system is a contained, manageable work unit that includes an

empowered work team, equipment and work to be executed. A group of 4-17 people who
set their own standards and work together to produce a finished garment. They work as a
team or module and each team member works on more than one operation.

● Before a firm can establish a MPS, it must prioritise its goals and make decisions that
reflect the needs of the firm. The team is responsible for maintaining a smooth workflow.

● The system was first implemented at company Toyota in 1978 as part of JIT, and was
known in the 1980s in the West as the Toyota Sewing System.

● The modular system works on the principle of pull-type production systems, in which the
job order comes from the last step to previous steps.
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Image Source: 8
https://textilestudycenter.com/modular-production-system-cellular-garment-manufacturing-toyota-sewing-system/#:~:text=Modular
 02

Features and
Applications of
Modular
Production
System
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 Features
● Module is divided into several work zones
● Usually U-shaped layout with more workplaces than operators.
● Required multi-skilled workers and a small set of machines.
● Every operator performs approximately 2-4 operations
● Walking is very minimal for the operators
● Workflow is sequential, WIP inventory is less and Productivity is high
● Addresses the causes of defects and machine problems that cause delays
● The operators stand or sit at their stations and rotate in different sewing machines
● Pull-type production systems, in which the job order arrives from the last step to
previous steps
● Time spent per garment is also very little 10
 Applications of Modular Production System

● Fashion garments with quick response.

● Orders with low volume and frequent
changes.
● Company with mutual trust between
management and operators.
https://textilestudycenter.com/garm
ent-production-system/
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 03

Process of
Modular
Production
System
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 Process of Modular Production System

● Flexible Manufacturing System

● Enhances multi-skill development of
operators
● Modular manufacturing groups operate in
teams, or modules
● Enhances quality and reduces worker
turnover Image Source: https://textilestudycenter.com/garment-production-system/

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Style Complexity

14
Modular Section

● Zero Changeovers
● Increase Productivity
● Decrease in Throughput

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 04

Advantages of
Modular
Production
System
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 Advantages

● The amount produced can easily be arranged by changing the

number of operators working in the system.
● Leads to cost savings.
● Highly flexible and permits better line balancing.
● The amount of work in progress is low, even working when no
inventory is possible.
● Enables fast throughput time, lower WIP, and small batch size can
be achieved.
Image Source: https://www.indiamart.com/proddetail/apparel-
● Encourages a team spirit and discourages absenteeism. manufacturing-technology-19589445297.html

● Increases Productivity

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● Reduces supplies of unfinished production
● Requires less floor space
● Reduces transport and unnecessary handling
● Allows adjustment of frequent changes design
of clothes, models, small and medium size work
order
● Faster flow of materials, rational use of the
existing machine, increased productivity as well
as quality in small batches and allows industrial
production to measure
● Low wastages Image Source: https://www.indiamart.com/proddetail/ladies-garments-manufacturing-
20655813097.html
● Improved quality of the product

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 05

Disadvantages
of Modular
Production
System
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 Disadvantages

● A high capital investment in equipment.

● High capital investment is needed in initial training workers to deal with several tasks
at one station.
● High cost incurred in continued training
● This system requires a higher degree of communication and cooperation among
operators, mechanics, and supervisors.
● Operators cannot develop the rhythm and pace of high performance.
● No harmony between team members can cause problems, thus loss in production.
● Depend on the Team for whole Production.

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 06

Comparison
with other
Production
Systems
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 PBS vs MPS

● Apparel retailers need to respond quickly to the changing market

● The apparel assembly in the traditional apparel manufacturing is very time-consuming
Comparison
Progressive Bundle System Modular Production System

In MPS, the module, which consists of a group

In PBS, each operation is done by a single
worker who operates a stationary machine. of workers, is in charge of a part of, sometimes
a whole, garment.

The main philosophy behind PBS is maximizing The main philosophy is to employ the more
the utilization of each worker’s working flexible production systems for the apparel
capacity. assembly

Throughput Time is Long Throughput Time is Long

Work in Progress (WIP) inventory is high Work in Progress (WIP) inventory is low

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 Flexible - Modular Production System

● Optimal Design for Manufacture

● MPS is the perfect solution for the
apparel manufacturer to respond to the
quick replenishment requirement by the
retailers.
● The diffusion of MPS in the apparel
industry is slow.
● The modifications of human resource
practices pose a huge work that affect a Image Source: https://textilestudycenter.com/modular-production-system-
cellular-garment-manufacturing-toyota-sewing-system/
lot the throughput and replenishment
speed
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 07

Conclusion

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Design for manufacture has gained widespread recognition as a means of reducing production
costs and lead times. MPS is the perfect solution for the apparel manufacturer to respond to
the quick replenishment requirement by the retailers. Although MPS can provide obvious
benefits for the apparel manufacturers, the diffusion of MPS in the apparel industry is slow.
The possible reasons for this phenomenon are studied by the researchers, most from the
perspective of human resource practices
The modifications of human resource practices pose a huge work for the apparel
manufacturers who want to adopt to MPS, and the results of those modifications affect a lot
the throughput and replenishment speed the manufacturer could achieve.

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 References

● https://textilestudycenter.com/modular-production-system-cellular-garment-manufacturing-toyota-sewing-
system/#:~:text=Modular%20production%20system%20involves%20a,on%20more%20than%20one%20o
peration
.
● https://medium.com/@zahir110199/modular-production-system-toyota-sewing-system-cellular-garment-m
anufacturing-system-c77a5855635b
● https://medium.com/@zahir110199/modular-production-system-toyota-sewing-system-cellular-garment-m
anufacturing-system-c77a5855635b
● https://www.researchgate.net/publication/260197357_Modular_Manufacturing_in_Garment_Industries
● https://www.ijser.org/researchpaper/Application-of-Modularmanufacturing-System-in-Garment-Industries.
pdf
● https://www.slideshare.net/DrSKathirveluSubrama/garment-production-systems-76962841
● https://www.onlineclothingstudy.com/2011/09/garment-production-systems.html
● http://gordanacolovic.blogspot.com/2013/10/modular-production-system.html
● https://indiantextilejournal.com/articles/FAdetails.asp?id=1988

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Thank You!

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