Production Between a Traditional Bundle System Cost

Comparison of Cost and Production Between a Traditional Bundle System and a Unit Production System

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I was earlier complaining about not having much study materials on the net for us. Study materials like articles on various topics related to Garment Production, Technology, Did-it-Yourself Guides, Tutorials etc. Do you also think so?


Now I would say that I was wrong. Actually there are enough study materials for learning from the net. Just we need to become smart in searching in Google.


Yesterday I discovered one such valuable document (A Research Report) from Fashion Institute of Technology's Advanced Apparel Manufacturing Technology Department (AAMTD). This research report is the result of work performed under sponsorship of the Fashion Institute of Technology and the United States Department of Defense, Defense Logistics Agency.


You can Read this research Paper. This report explains facts related to Traditional Bundle System (PBS) and Unit Production system (UPS) and Apparel Production Methods. And shows comparison of Cost and Production between PBS and UPS installation.


Comparison in Brief from the report

"A manufacturer that was using a bundle system switched over to a UPS. Data critical to an analysis of the two systems was collected prior to and after the changeover and then was critically analyzed. Analysis revealed that with the UPS installation weekly output increased by 9.6%; the number of workers decreased by 10.3%; production time per unit decreased by 17.3%; and, unit production costs decreased by 12.3%", as reported by author of this research paper. 

Increase Garment Production and Floor Performance

Tips to Increase Production and Floor Performance

There are many heavy duty theories for improving production in garment industry. Many of us go for implementing such difficult-to-understand and difficult-to-apply methods. Somehow we forget to apply simple things those have enough potential to bring improvement in production.


Floor performance can be improved by saving time, increasing production, saving cost of production, increasing workers heath and safety etc. All these possible by taking care of small things. To make your factory better and improve overall performance, keep your eyes in small things as well. Bring changes that gives you greater benefits.

Following are the simple and easy to apply tips. Most of these tips are on prior preparation and discipline. Practice and get BIG benefits from small changes in your daily work. Read the full list.

1. Don't accept incomplete production file from merchandising team to start production functions
2. Prepare line loading plan in advance to avoid waiting after production starts
3. Balance lines to avoid bottleneck
4. Keep enough WIP to feed the line whole day
5. Don't allow to generate excess inventory. Excess WIP in line may reduce line/batch performance
6. Provide extra bobbin to operators. This simple practice saves time in refilling the empty bobbin
7. Feed defect free cutting to line
8. Save time by quick replacement of broken needles and empty thread spools 
9. Only feed ready cuttings (component) to sewing lines. Don't allow re-cutting and trimming of components in line
10. Use of UBT machine - it improves quality and improves performance
11. Keep floors and table tops neat and clean - it improves employee productivity
12. Don't keep any obstruction on the walking space in floors
13. Design workstation layout considering motion economy
14. Keep spare machines for quick replacement at the time of machine break-down
15. Schedule regular machine maintenance and follow the schedule
16. Use work aids, guides and attachment wherever applicable
17. Avoid parts matching at machine (by operator), if required keep one helper for part matching 
18. Capture hourly production data and make hourly production report, display it in front of the line
19. Don't give back defective garments to the running line. 
20. Don't distract operators from their work
21. Bonus tip: Keep drinking water dispenser as near as possible to sewing section

Start implementing tips that you find easy for you to implement. You can also share your tips that you practice in day to day work.

Sampling Merchandiser and Production Merchandiser

Difference between Sampling Merchandiser and Production Merchandise

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You might hear merchandising job profile. In garment manufacturing merchandisers play very important role. You might also hear the term ‘Sampling Merchandiser’ and ‘Production Merchandiser’. Do you know the differences between these two job profiles are?

Though there are no fixed rules for job responsibilities of these two job profiles. We can draw difference between a sampling merchant and a production merchant based on day to day activities performed by them.

Normally small size garment manufacturing companies don't employ different merchandisers for such different roles for sampling and production activities. All activities are looked after by the same merchant. So they are not given such name as sampling merchant or production merchant. In medium and large size garment manufacturing companies, different teams are found for sampling activities and production related activities. Even some companies have separate set-up or office for sampling. 

In case there are merchandisers in two different profiles in a company following are the difference activities. Read following activities to understand difference between sampling merchandiser and production merchandiser.

Sampling Merchandiser:

Sampling merchandisers are responsible for sampling activities, which includes followings.

• Coordination with buyer related to sampling requirement - they communicate with buyers for sampling process.
• Product development – fabric development and sample development is handled by them. 
• Handing sampling team – Many cases it is found that merchandisers handle sampling team. 
• Preparation of sampling order for the sampling tailors – merchandised receive style techpack from the buyers and explain style requirement and style detailing to sampling master (sampling in-charge) and pattern master. Also they explain buyer's comments on samples to sampling head and tailors. 
• Correcting pattern based on FIT and Size set comments 
• Looking into quality aspect of the samples 
• Following up sampling processes end to end 
• Development of Trims and fabric 
• Development print and embroidery sample 
• Sourcing of trims and accessories for sample development 
• Submission of sample to buyer and follow up sample approvals 
• Coordinating with production merchandiser for production orders 
• Handing over sampling comments and style files to production merchant 

Production Merchandiser

Activities of production merchant starts after receiving of purchase orders (PO). Production merchandisers take handover of style file from sampling merchandiser. They prepare schedule for production activities. Follow up with production team and with factories if factory has multiple production units. There responsibility ends after shipment is dispatched to buyer.

Activities of a production merchandiser have been explained in an earlier post. Please read to know the difference between these merchandisers.