Progressive Bundle System and Unit Production System (UPS)
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Apparel Manufacturing n Marketing
In
the industrial sewing plants various types of sewing systems are installed. A
plant owner chooses these systems depending on the production volume, product
categories, and cost effectiveness of high tech machineries. Among those
“Progressive Bundle System” (PBS) is mostly installed sewing system till
date. In this production system bundles of cut pieces (bundle of 5, 10, 20 or
30 pieces) are moved manually to feed the line. Then inside the line an
operator himself drag the bundle from side table and transfer the bundle to
the next operator
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after
completion of the work. With the advancement of the technology mechanical
material transportation systems are brought in the sewing plant. An overhead
material transport system, known as UPS (Unit Production System) transports cut
pieces hanged in hangers (one hanger for one piece) by automated mechanical
transport system. It reduces manual transportation and it has many other
benefits against the progressive bundle system. This article is not to
recommend one to replace this well placed progressive bundle system. When to
install a new technology is depend on various factors. A comparison between
these two production systems has been drawn in the following table on the basis
of production KPIs (Key Performance Indicators) to show how an UPS system
(overhead hanging and sensor controlled system) is most effective over PBS.
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Parameters
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Progressive Bundle
System (PBS)
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Unit Production
System (UPS)
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Transportation
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-Manual
transportation, many times helper are hired for this bundle transportation
job.
-Operators
stop their work to fetch bundles.
-Less
effective in terms of production management. Resulted long response time.
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-In
this system an automated mechanical system carries pieces to each work
stations.
-Easier
pick up and dispose at each work station. Resulted quick response time
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Through put time
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-Compare
to UPS, through put time longer in PBS. How much long will depend on the
bundle size and no. of bundles kept in between two operators.
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-Through
put time in UPS is less compare to PBS. But it is not the minimum time as in
this system there is WIP in between two operators.
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Direct Labour content
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-
Direct labour content is high because usually operator does tying and untying
of bundles, positioning components, pulling the bundle ticket and handling of
work pieces.
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-Direct
labour content is less than PBS because an operator only sews the garment
part rather than other tasks. In this system garment parts are held by the
over head hanger, so less handling of garment components.
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WIP level
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-In
PBS generally operators are asked to sew as much pieces as they can without
considering back and front operators. This resulted piling up of work in the
operations with higher work content.
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-Less
WIP in between operators. As workstation has limit of holding no. of hangers.
Also after completion of operation hangers are transported to the next
operation automatically.
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Cutting work requirement
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-As
a result of High Work In Process (WIP) is required by sewing section, cutting
sections are required to perform 60-70% more than actual production can
handle.
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-Lower
WIP results in less cutting works. A balanced flow of material established in
between cutting and sewing line.
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Inventory Level
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-Due
high WIP and higher cutting, fabrics and trims need to stock in advance
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-Less
inventory for fabric and trims.
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Excess labour requirement
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-
Usually in PBS needs more overtime works, repair work due to some unfinished
operations.
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-Plant
with UPS system needs less overtime as planning is easy in this manufacturing
system.
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