“GARMENT PRODUCTION
SYSTEM”
Presented By: Dimple
Student of Apparel production management
Institute of Apparel production management
Individual system/Make
through/Whole garment system
This is the traditional method of production whereby one
operator assembles the entire garment.
Here a tailor to performs nearly every operation required to
make the garment, including machining, hand work and
pressing.
In this production system the operator would be given a
bundle of cut work and would proceed to sew it according to
his or her own method of work.
The labour required by this system must be
highly skilled and versatile, which makes this
system expensive.
This system is effective when a very large
variety of garments have to be produced in
extremely small quantities.
Whole Garment Production System
There are two types of Whole Garment
Production Systems:
1.
Complete whole garment .
2.
Departmental whole garment.
1. Whole garment production
system
One individual makes the entire garment from cutting the
cloth to sewing and pressing the garment. The garment is
ready for dispatch once the operator completes the final
operation.
 This type of system is used in a few places, which are
engaged in custom-wholesale. They are normally high priced
and exclusively made for a particular customer. They are
limited in number and distribution; normally about 10-20
garment are made.…………………………………………...
2. Departmental whole garment
system
One individual does all the work with the equipment
allocated to a department.
 For example, one person does all the cutting work in
cutting department, second person does all the sewing
work in sewing department, and the third person does the
pressing and packing work.
The workers in this system may use more than one
equipment to complete their respective job.
Advantages
More effective when a very large variety of garments in
extremely small quantities.
In piece rate system the operators will do with full
involvement:To finish more pieces, to earn more money.
Operator will be specialized in his own working area.
The Work in Progress (WIP) is reduced, at a time one cut
garment to one operator and so the amount as inventory is
reduced.
Disadvantages
Highly skilled laborers are used, so the cost of labor is high.
The operator is more concerned on the number of pieces
finished rather than the quality of work.
Productivity is less due to lack of specialization.
For long run/bulk quantity of same style is not effective in
this system.
Garment Production System
In simple a ‘garment production system’ is a way how
fabric is being converted into garment in a
manufacturing system.
 The choice of best apparel production system depend
on the Product, The Policies of the Company and the
capacities of manpower.

There are two Production systems:
1. Progressive Bundle System
2. Unit Production System

1. Progressive Bundle System (PBS)
implies the bundle of garment parts move from
operation to operation.
 TraditionaAlso Called Material Handling System.
 As name l Production system.
 Widely used by apparel manufacturers for several
decades and still today.
 80% apparel manufacturers use the Bundle system
(PBS).

PBS Workflow
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Bundles consist of garment parts needed to complete a
specific operation (e.g an operation bundle for pocket
setting might include shirt fronts and pockets to b
stitched together.
Some firms operate with a standard bundle size, while
other vary bundle sizes acc. to size of pieces in bundle
and operation to b completed.
Bundles are assembled in the cutting room, where cut
parts are matched up with corresponding parts and
bundle tickets.
Workers (labour) transport and move Bundles of cut
parts to sewing room via trollies.
Operator scheduled to complete the operation and
perform same operation on all pieces in the bundle,
retie the bundle, remove Bundle ticket and move bundle
for next operation.
Progressive Bundle System
Advantages of PBS
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Labor of all levels ie unskilled, skilled, semi skilled labors
are involved. Small simple operations.
Quantity of each operation is checked during every
single operation thus quality is good.
Due to bundle system, less chance of mixing up of
parts…thus less confusion.
Bundle tracking is possible, so identifying and solving
problems become easy.
Effective production control system and Quality control
system.
Dis-advantages of PBS
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Time Consuming due to assembling, moving and untieing of bundles.
More labor…More labor cost.
Needs efficient supervisor.
Labor absentiees can effect production due to
incompletion of contracts.
Variety of styles and less quantity is not effective in
this system.
Proper planning is required for each style, each batch.
Improper planning causes labour turnover, poor
quality, less production, etc.
2. Unit Production System (UPS)
A Unit Production System is a type of layout that
uses an overhead transporter system to move
garment components from work station to work
station for assembly.
 In UPS, there are hangers. One hanger have multiple
clips containing all parts of the single garment.
 All parts for the single garment are advanced through
stitching line together by means of hanging carrier
that moves along an overhead conveyor.
 Hanging carrier can be moved manually by the
operator using button after completion of single
operation or By computerized system that move
the conveyor after a specific fed throughput time.

UPS Workflow
Load all the pieces of single garment in a product
carrier.
 The product carrier with the pieces will be routed
through the different operation steps.
 At every machine/operation the patented chain will
position the product ideally.
 Completed the product arrives to an unloading station.
The empty product carrier returns to the loading
station.

Unit Production System
Advantages of UPS
Bundle Handling completely eliminated.
 The time involved in the pick-up and disposal is reduced
to minimum.
 Output is automatically recorded, eliminates the
operator to register the work.
 The computerized system automatically balance the
work between stations.
 Improved lead times-less work in process.
 Improved space utilization (more machines can be
adjusted)
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Advantages of UPS (Cont.)
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Increased Productivity.
Throughput time can be drastically reduced.
Indirect labor costs are reduced (by elimination of
bundle handling and requiring fewer supervisors)
Improved production and quality.
Dis-advantages of UPS
Unit Production system requires high investment.
 Proper planning is required to be effective.
 Highly expensive-buying equipment and cost
installing.
 Specialized training for the system.
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