Production System

Production cheeks What is a drudgery organization? An app arl w ar system of rules is an integration of strong handling toil figure out, personnel and the equipment that directs hit wee-wee it away and gene rank finished ingatherings. incompatible types of fruit systems argon Progressive bunch up system building block achievement system Modular out stray system Each system requires an give up management school of thought, materials handling methods, floor layout, and Employee training. Firms may combine or conciliate these systems to meet their specific output signal sine qua nons.Firms may usage only nonpareil system, a combination of systems for one Product disputation, or distinguishable systems for different product lines in the same plant. Progressive Bundle system The forward accumulate system (PBS) gets its name from the pack togethers of set split that are travel sequentially from effect to surgery. This system, often referred to as th e conventional proceeds system, has been astray subroutined by apparel manufacturers for several decades and still is today. The expert says that procedure of pile systems would decrease as theaters seek more tractableness in their employment systems picWork flow in modernised galvanic pile system Bundles represent of prune parts indispensable to complete a specific operation or garment component. For example, an operation big money for pocket setting exponent include shirt fronts and pockets that are to be attached. Bundle sizes may track down from cardinal to a hundred parts. approximately firms operate with a exemplification bundle size, bit other firms vary bundle sizes correspond to penetrating orders, fabric shading, size of the pieces in the bundle, and the operation that is to be completed. Bundles are assembled in the cutting fashion where cut parts are fight downed up with comparable parts and bundle tickets.Bundles of cut parts are transported to t he sewing populate and habituated to the instrument scheduled to complete the operation. One operator is pass judgment to perform the same operation on all the pieces in the bundle, tie the bundle, make coupon, and set it aside until it is picked up and moved to the next operation. A progressive bundle system may require a spicy volume of buy the farm in process cause of the consequence of units in the bundles and the macro(p) buffer of backup that is needed to ensure a nonstop determine flow for all operators. pic The progressive bundle systemThe progressive bundle system may be utilise with a skill heart or line layout depending on the order that bundles are advanced through and through output. Each style may have different processing requirements and hence different routing. Routing identifies basic operations, sequence of production, and the skill centers where those operations are to be performed. rough operations are common to m any(prenominal) styles, and a t those operations, belong may build up waiting to be processed. Advantages and disadvantages of using progressive bundle system AdvantagesThe advantage of a bundle system may depend on how the system is set up and used in a plant. This system may allow better utilization of change cable cars, as output from one special purpose automated machine may be able to supply several operators for the next operation. smooth bundles allow faster throughput unless there are bottlenecks and extensive waiting amidst operations. Disadvantages The progressive bundle system is driven by cost strength for individual operations. streetwalkers perform the same operation on a inveterate basis, which allows them to increase their speed and productivity.Operators who are compensated by piece rates become extremely efficient at one operation and may not be willing to learn a new operation because it reduces their efficiency and earnings. Individual operators that hit in a progressive bundle syst em are independent of other operators and the final product. Slow processing, absenteeism, and equipment reverse may also cause major bottlenecks inwardly the system. Large quantities of take a crap in process are often characteristic of this type of production system.This may lead to longer throughput time, poor quality out of sight by bundles, large neckc exercise seth, extra handling, and difficulty in breakling inventory Unit production system A unit production system (UPS) is a type of line layout that uses an disk overhead transporter system to move garment components from movement station to work station for Assembly pic Work flow of unit production All the parts for a unity garment are advanced through the production line together by meat of a suspension carrier that travels along an overhead conveyor.The overhead rail system consists of the main conveyor and accumulating rails for severally work station. The overhead conveyor operates much like a railroad track. Carriers are moved along the main conveyor and switched to an accumulating rail at the work station where an operation is to be performed. At the completion of an operation the operator presses a thatton, and the carrier moves on to the next operation. Most unit production systems are linked to a computer restrain center that routes and tracks production and provides up-to-the-minute data for management decisions. The utomatic lock of work flow sorts work, balances the line, and reduces claims of favoritism in bundle distribution. Electronic data collection provides payroll and inventory data, immediate tracking of styles, and costing and performance data for prompt decisions. process begins at a staging area in the sewing room. twist parts for one unit of a single style are sorted and loaded directly from the staging area to a hanging carrier. Loading is carefully planned so minimal handling is undeniable to deliver garment parts in precisely the order and dash that they wi ll be sewn.When possible, operations are completed without removing the parts from the carrier. alter sizes and types of hanging carriers are available for different types of products. Automated materials handling replaces the traditional system of bundling, tying and untying, and manually moving garment parts. Unit production systems eliminate well-nigh of the lifting and turning needed to handle bundles and garment parts. The need for bundle tickets and processing operator coupons is also eliminated when an integrated computer system monitors the work of all(prenominal) operator.Individual bar codes or electronic devices are introduce in the carriers and read by a bar code digital s burn downner at for each one workstation and control points. Any data that are needed for sorting and processing such as style number, color shade, and lot can be included. Integrated systems have on-line terminals located at each work station to collect data on each operation. Each operator may advance completed units, reroute units that need indemnify or processing to a different station, and check their efficiencies and earnings Operator may signal for more inventory or call for a supervisor if assistance is needed.The terminals at each station enables central control center to track each unit at any given moment and provide management with data to make immediate decisions on routing and scheduling. Operators of the UPS control center can determine sequences of orders and colors to keep operators supplied with work and to minimize change in equipment, operations, and thread colors. A unit production system can control eight-f elderly routes and simultaneous production of multiple styles without restructuring production lines. The control center may perform routing and automatic fit of work flow, which reduces bottlenecks and work stoppages.Each operator as well as the control center is able to monitor individual work history. individual unit, number of units completed , the operator who worked on each unit, and the piece rate earned for each unit. The system will calculate the earnings per hour, per day, and the efficiency rate of each operator. Advantages Benefits of a unit production system depend on how a system is used and the effectiveness of management. Throughput time in the sewing room can be drastically bring down when compared to the progressive bundle system because works in process levels are reduced.Operator productivity increases. Direct push costs are reduced because of propositioned parts in the carriers and elimination of bundle processing. Indirect get the picture costs may be reduced by elimination of bundle handling and requiring fewer supervisors. Quality is better because of business of all operators and immediate visibility of paradoxs that are no longer concealed in bundles for extended periods of time. The central control system makes it possible to at a time track a quality task to the operator that completed the operation.Other benefits that are realized are improved attendance and employee turnover and reduced situation utilization. Disadvantages Considerations for installing a UPS include costs of buying equipment, cost of installing, specialize training for the system, and prevention of downtime. Down time is a potential problem with any of the systems, but the low work in process that is kept up(p) makes UPS particularly vulnerable. Modular Production System A standard production system is a contained, manageable work unit that includes an empowered work team, equipment, and work to be executed.Modules frequently operate as minifactories with teams responsible for group goals and self-management. The number of teams in a plant varies with the size and require of the firm and product line. Teams can have a niche function as long as there are orders for that type of product, but the success of this type of operation is in the flexibility of being able to offer a wide variety show of products in footling quantities. The numbers of employees on a team, commonly 4 to 15, vary with the product mix. A familiar rule of thumb is to determine the average number of operations undeniable for a style being produced and divide by three.Team members cross- practised and interchangeable among tasks within the group. Incentive compensation is based on group pay and bonuses for impact team goals for output and quality. Individual incentive compensation is not countenance for team-based production. Teams may be used to perform all the operations or a certain portion of the assembly operations depending on the organization of the module and processes required. Before a firm can establish a standard production system, it must prioritize its goals and make decisions that reflect the ineluctably of the firm.With a team-based system operators are given the responsibility for run their module to meet goals for throughput and quality. The team is responsible for maintainin g a smooth work flow, clashing production goals, maintaining a specified quality level, and handling motivational deliver for the team. Team members develop an interdependency to improve the process and accomplish their goals. mutualness is the relationship among team members that utilizes everyones strengths for the betterment of the team. Work flow in modular production system picA Modular Production System operates as a Pull System, with demand for work coming from the next operator in line to process the garment. Wastage is normal, and workflow is continuous and does not wait fore of each operation. This increases the potentials for flexibility of styles and quantities of products that can be produced. Teams usually operate as Stand-up or Sit-down units A module may be divided into several work zones based on the sequence of operations and the time required for each operation. A work zone consists of a group of sequential operations. Operators are trained to perform the opera tions in their work zone and djacent operations in adjoining work zones so they can move freely from one operation to another as the garment progresses Work flow within a module may be with a Single-piece hand-off, Kanban, or Bump- back system. If a single-piece hand-off is used, machines are ar diverged in a very tight configuration. As soon as an operation is completed the part is handed to the next operator for processing. operations need to be well balanced as there is usually only one garment component between each operation. Some modules may operate with a buffer or small bundle of up to ten pieces of work between operators.If a small bundle is used, an operator will complete the operation on the ideal bundle and carry the bundle to the next operation. An operator may follow a component or bundle for as many operations as they have been trained or until the adjacent operator is ready to take aim work on the bundle Advantages of a Modular Production System are 1. ) High flex ibility 2. ) Fast throughput times 3. ) Low wastages 4. ) cut Absenteeism 5. ) Reduced Repetitive Motion Ailments 6. ) Increased employee ownership of the production process 7. ) Empowered employees 8. ) Improved QualityDisadvantages of Modular Production System 1. ) A blue capital investment in equipment. 2. ) High investment in sign training. 3. ) High cost incurred in continued training Combinations of Production Systems Some firms may use the progressive bundle system for producing small parts Combined with modular production for garment assembly. This reduces the investment in change equipment and reduces the team size needed. Some manufacturing consultants believe that a modular system combined with a unit production system provides the virtually flexibility, fastest throughput, and most consistent quality.This would be particularly useful for large items such as coveralls or heavy coats. The UPS would move the garment kind of of the operators. Each manufacturer needs t o determine what is best for its product line and production requirements. The another major and oldest production system followed in industry is TOYOTA PRODUCTION SYSTEM (TPS) Toyota production system pic History of (TPS) The production system developed by Toyota take Corporation to provide best quality, concluding cost, and shortest lead time through the elimination of waste.Development of TPS is credited to Taiichi Ohno, Toyotas chief of production in post-WWII period. Beginning in machining operation and spreading from there, Ohno led the festering of TPS at Toyota throughout the 1950s and 1960s and the dissemination to the supply base through the 1960s and 1970s. Toyota Motor Corporations vehicle production system is a way of qualification things that is sometimes referred to as a lean manufacturing system or a Just-in-Time (JIT) system, and has come to be well known and studied worldwide.Then, in 1924, Sakichi invented the worlds first automatic loom, called the Type-G Toy oda Automatic Loom (with non-stop shuttle-change motion) which could change shuttles without stopping operation. The Toyota term jido is applied to a machine with a built-in device for making judgments, whereas the regular Japanese term jido ( mechanization) is only when applied to a machine that moves on its own. Jidoka refers to automation with a human touch, as opposed to a machine that simply moves under the monitoring and supervision of an operator. Since the loom stopped when a problem arose, no defective products were produced. This meant that a single operator could be put in charge of numerous looms, takeing in a tremendous service in productivity. pic Just in time Just-in-time is a management philosophy and not a technique.Just-in-Time means making only what is needed, when it is needed, and in the kernel needed. To efficiently produce a large number of products such as automobiles, which are comprised of some 30,000 parts, it is necessary to create a detailed product ion plan that includes parts procurement, for example. Supplying what is needed, when it is needed, and in the amount needed according to this production plan can eliminate waste, inconsistencies, and unreasonable requirements, resulting in improved productivity. Kanban system pic Kanban is a production system its a part of toyato production or lean manufacturing system Kanban is a Japanese word which means signal cards. These cards are hung where ever required o only when this card indicated that the particular space is empty the products are change back in the tray This is a simple concept, but very effective. Kanban mainly focus on the reduction of overproduction. The is also interlinked with the Toyota production system In the TPS, a unique production control method called the Kanban system plays an burning(prenominal) role. The Kanban system has also been called the Supermarket method because the idea behind it was borrowed from supermarkets. Supermarkets and mass merchandiz ing stores use product control cards on which product-related information, such as product name, product code, and storage location, is entered.Because Toyota employed Kanban signs in place of the cards for use in production processes, the method came to be called the Kanban system. At Toyota, when a process goes to the preceding process to retrieve parts, it uses a Kanban to communicate what parts have been used. Here a Kanban system is used pic There are two kinds of Kanban Production instruction Kanban Parts retrieval kanban cubicleular manufacturing What is cellular manufacturing? Cellular manufacturing, sometimes called cellular or cell production, ar stoves factory floor labor into semi-autonomous and multi-skilled teams, or work cells, who manufacture complete products or complex components.Properly trained and implemented cells are more flexible and responsive than the traditional mass-production line, and can manage processes, defects, scheduling, equipment maintenance, and other manufacturing issues more efficiently pic History Cellular manufacturing is a fairly new application of group technology, although the Portsmouth Block Mills offers what by definition constitutes an early example of cellular manufacturing. By 1808, using machinery intentional by Marc Isambard Brunel and constructed by Henry Maudslay, the Block Mills were producting 130,000 blocks (pulleys) for the Royal dark blue per year in single unit lots, with 10 men operating 42 machines arranged in three production flow lines. This inductance apparently reduced manpower requirements by 90% (from 110 to 10), reduced cost substantially and greatly improved block consistency and quality.Group engine room is a management strategy with long term goals of staying in business, growing, and making profits. Companies are under relentless pressure to reduce costs patch meeting the high quality expectations of the customer to maintain a competitive advantage. Successfully implementing Ce llular manufacturing allows companies to achieve cost savings and quality improvements, especially when combined with the other aspects of lean manufacturing. Cell manufacturing systems are currently used to manufacture anything from hydraulic and engine pumps used in aircraft to plastic packaging components made using injection molding. Goals of cellular manufacturingThe goal of cellular manufacturing is having the flexibility to produce a high variety of low demand products, while maintaining the high productivity of large scale production. Cell creationers achieve this through modularity in both process design and product design. Process design The division of the entire production process into discrete segments, and the assignment of each segment to a work cell, introduces the modularity of processes. If any segment of the process needs to be changed, only the particular cell would be affected, not the entire production line. For example, if a particular component was prone to defects, and this could be resolved by upgrading the equipment, a new work cell could be designed and prepared while the obsolete cell continued production.Once the new cell is tested and ready for production, the incoming parts to and outgoing parts from the old cell will simply be rerouted to the new cell without having to split up the entire production line. In this way, work cells enable the flexibility to shape up processes and make variations to products to better suit customer demands while largely reduction or eliminating the costs of stoppages. Product Design Product modularity must match the modularity of processes. Even though the entire production system becomes more flexible, each individual cell is still optimised for a relatively narrow range of tasks, in order to take advantage of the mass-production efficiencies of specialisation and scale.To the extent that a large variety of products can be designed to be assembled from a small number of modular parts, both h igh product variety and high productivity can be achieved. For example, a varied range of automobiles may be designed to use the same chassis, a small number of engine configurations, and a moderate variety of car bodies, each available in a range of colors. In this way, a large variety of automobiles, with different performances and appearances and functions, can be produced by combining the outputs from a more limited number of work cells. In combination, each modular part is designed for a particular work cell, or utilise clusters of machines or manufacturing processes.Cells are usually bigger than typical conventional workstations, but smaller than a complete conventional department. After conversion, a cellular manufacturing layout usually requires less floor space as a result of the optimized production processes. Each cell is responsible for its own internal control of quality, scheduling, ordering, and record keeping. The idea is to place the responsibility of these tasks o n those who are most familiar with the situation and most able to quickly fix any problems. The middle management no longer has to monitor the outputs and interrelationships of every single worker, and instead only has to monitor a smaller number of work cells and the flow of materials between them, often achieved using a system of kanbans