ADM 4307 Apparel Manufacturing

By Dr. Su-Jeong Hwang Shin, Ph.D. Associate Professor

Productivity concept: 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).

(Input) Materials

(Output) Salable Garments

•High efficiency•Low-cost work•Maximize productivity

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

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

Workflow: 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:

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.

Just-In-Time (JIT) delivery is an operational strategy that coordinates arrival of goods with immediate use and minimal handing.

Progressive Bundle System (PBS): 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

Unit Production System (UPS): A type of line layout that

uses an overhead transporter system to move garment 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.

Modular Production System: Modular production system

is a contained, manageable work unit that includes an empowered work team, equipment, and work to be executed.

Management and team training for empowerment (Team-based production system).

Workflow in modular production Work zone consists of a group

of sequential operations (Toyota Sewing System, TSS).

Production process: An operation breakdown is a

sequential list of all the operations involved in cutting, sewing, and finishing a garment, component, or style.

Work study: the analysis of the operations

required to produce a style. 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) 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 strategies: Mass customizationMass customization requires processing single

orders with immediate turnaround. The goal of mass customization is to be agile

enough so products can be made-to-order. (fully customized style, fit, fabric, and trim with delivery direct to home). Example: Body scanning technology for custom fit.

Production Planning Long term production planning: Based on forecasts merchandise plans, and budgets

Short term production planning: Based on customer orders

Production capacity (output): Factors affect Output capacity Space utilization and limitation Equipment type The size, skill, and productivity of the labor Product variation.

Capacity Plant capacity Individual operation capacity Relationship of production standards to capacity (SAMs or SAHs) Managing plant capacity Learning curve application.