Production System

Production system: Production system may be classified into two manufacturing system

Push system: It is conventionally western system of manufacturing. Western industries conventionally plan the activities backwards from the delivery date of product and identify how many of sub-assemblies, fabricated parts, purchased units and materials should be made available finished items are pushed through the workstations. This means that when the operation on item of a lot is complete, the lot is. Moved to the next workstation without considering the availability of this (next) workstation. The outcomes of the push system are

1) Every workstation (both man and m/c) has high time utilization
2) Material has large through put time, increasing the WIPI and the product (about 5% of the through-put time is actual materials processed time)
3) Workers are task-oriented (having special skill). The worker are at each work station perform their specialized tasks on every unit of lot. Because of the repetitive nature of the work the demand on output quality. At each workstation is not fixed. Defective parts produced.

Classification of push system.
 1) Progressive bundle system (PBS)
 2) Unit production system (UPS) PROGRESSIVE BUNDLE SYSTEM: The progressive bundle system gets its name from bundles of garments part that are moyed sequentially from operation to operation.

A bundle consists of garment parts feeded to complete a specific operation or garment component. Bundles are assembled in cutting room where parts are matched up with corresponding parts and bundle tickets. Bundles tickets consists of master has of operations and corresponding coupon for each operation. Each bundle receives a ticket that identifies the style number, size, shade, list of operations for routing, and the piece rate system for each operation. Operators retain a corresponding segment of bundle coupon for each bundle they completed. At the end of a workday, coupons are turned in, and earned time from the completed bundle tickets is totaled to determine the operator compensation. Advantage of progressive bundle system:

•  The progressive bundle system is driven by cost efficiency for individual operation. 
•  operator performs the same operation on a continuing basis, which allow them to increase their speed and productivity. 
•  Operator who are compensated by individual piece rates become extremely efficient at one operation. Disadvantage of the progressive bundle system: 
•  Operator work at different rates large quantities of work in process can build up ahead of some operation. 
•  Slow processing absenteeism, and equipment failure may also cause major bottlenecks within the system. 
•  Large quantities of work in process (WIP) is characteristic of this type of production system, this may leads to longer through put time (TPY) UNIT PRODUCTION SYSTEM: Unit production system (UPS) is a type line Layout that uses an overhead transport system to me individual from workstation to work station assembly. 

All the parts for a single game are advanced though the production line together by of hanging carrier that travels along conveyer. The work cycles being at staging area in the sewing room. Cuts parts for one unit of a single style are group and loaded directly form staging area to hanging carrier . Loading is carefully planned so minimum handling will be sewing. When possible operation are complete without removing the parts from the carrier. Pull production system MODULAR PRODUCTION SYSTEM: The term modular is used to identify the team approach to apparel production. It is contained a manageable work unit ( Module) that include an empowered work team. Equipment and work to be executed. Modules Frequently Operate as manufactures with team. Usually five to fifteen people .responsible for Group goal and self management. Team member are interchangeable among tasks within the group to the extent practical.