application of modular production system

Topics: Manufacturing, İzmir, Production system Pages: 5 (877 words) Published: September 30, 2013
MSc. Esra DİRGAR 1, Assoc. Prof. Dr. Ziynet ÖNDOĞAN 2


Ege University Bergama Vocation School, Bergama – Izmir / Turkey Ege University Engineering Faculty Textile Engineering Department, Bornova - Izmir / Turkey

Consumers now demand more variety in product lines and retailers expect faster delivery, better quality and lower costs. As global markets change, manufacturing strategies are also changing. Flexible manufacturing that strives to be responsive to customer demand. For the apparel manufacturing plant, flexible manufacturing means the capability to quickly and efficiently produce a variety of styles in small production runs with no defects. This may require philosophy changes, new performance criteria, effective use of new technology and beter development and use of resources than with traditional production systems. The underlying philosophy is that the manufacturing firm will operate with the flexibility needed to meet the needs of its customers and the inherent ability to adapt to immediate changes in the apparel market. Firms that are able to operate in a flexible manufacturing environment have a strategic advantage in the marketplace. Although flexible manufacturing involves the entire firm, much of the focus for improving flexibility has been on the production function.

An apparel production system is an integration of materials handling, production processes, personel and equipment that directs work flow and generates finished products. Two types of production systems that are commonly used to mass production in the apparel industry. These are progressive bundle system and modular production system.

In progressive bundle system, bundles of garment parts are moved sequentially from operation to operation. Bundles consist of garment parts needed to complete a spesific operation or garment component. For example; an operation bundle for pocket setting might include the shirt front and pockets to be attached. Bundle size may range from one part to a hundred parts. Operators perform the same operation on a continuous basis, which allows them to increase their speed and productivity. Large quantities of work in process are often characteristic of this type of production system. This may lead to longer throughput time, poor quality concealed by bundles, large inventory, extra handling and difficulty in controlling inventory. Also large quantities of work in process make it difficult to track spesific orders and provide flexibility for customers.

Figure 1. Progressive Bundle Production System

Modular production system is contained, manageable work unit that includes an empowered work team, equipment and work to be executed. Modules operates as minifactories with teams, usually five to fifteen people, responsible for group goals and self-management. Team members are interchangeable among tasks within the group to the extent practical. Incentive compensation is based on meeting team goals for output and the quality. Giving teams full responsibility for a finished product encourages group ownership of the product and its success, which includes the product quality, throughput and methods of assembly. Responsibility for the completed product builds a sense of accomplishment and motivation for team members. Quality becomes a team responsibility and therefore is monitored at the source. Researches shows a significant improvement in quality when the team is responsible for the quality of finished products. In modular system, it is possible to reach zero defect.

Figure 2. Modular Production System
In this study, two factories has been compared. One of them is carrying out progressive bundle system and the other is carrying out modular production system on apparel production. CONCLUSION
These two systems are compared ;

Bundle workers can be productive as soon as they learn one operation but module worker must be...

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