Learning Goal: Compare different production systems and select appropriate ones based on order and product.

Common systems:

  • Make‑Through (Whole‑Garment): One operator sews the entire garment. Used in sample rooms or for very small orders. High skill needed, low output.
  • Progressive Bundle System (PBS): The most common system. Bundles of cut pieces move from one operation to the next, each operator specialising in one or a few tasks. High efficiency but can create work‑in‑process (WIP) accumulation.
  • Unit Production System (UPS): An overhead transporter automatically moves individual pieces to workstations. Reduces WIP and handling, but requires investment.
  • Modular / Team Sewing: A small team of multi

skilled operators works together to complete a garment. Improves flexibility and quality, suited for quick style changes.

  • Straight‑Line / One‑Piece Flow: Each piece moves instantly to the next operation, minimal WIP. Requires highly balanced lines and quick operators.

Choosing a system depends on order quantity, product complexity, skill level, and delivery urgency.

Step‑by‑step Explanation:

  1. For a 20,000‑unit basic t‑shirt order, Progressive Bundle System with high specialisation is most efficient.
  2. For a 50‑piece designer dress with intricate details, Make‑Through or Modular may be better.
  3. A factory with high mix/low volume may invest in UPS to reduce bundle handling.
  4. Evaluate lead time, space, and capital before changing a system.

Best Practices: Even in PBS, keep bundle sizes small (10–15 pieces) to reduce WIP and improve tracking.

Common Mistakes: Using PBS for very small runs—operators spend too much time handling bundles, not sewing.

Real Industry Example: A fast‑fashion supplier uses a hybrid: PBS for core operations, but a modular team for special finishes, boosting both speed and flexibility.

Mini Case Study: A factory switched from PBS to modular for a complex ladies’ blouse and reduced throughput time by 30% because multi‑skilled operators adjusted quickly to different tasks, eliminating waiting time.

Practical Activity: Draw a simple diagram of a Progressive Bundle System for a shirt line and label the typical operation sequence.

Assignment: Write a one‑page comparison of PBS and Modular systems, recommending a system for a childrenswear factory with frequent style changes (200–500 units per style).

Lesson Summary: The production system shapes efficiency and flexibility; choose the one that aligns with your order profile and workforce capability.

Key Takeaways:

  • PBS is standard for large runs.
  • Modular and Make‑Through for smaller, complex orders.
  • UPS reduces handling but requires investment.
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