Manufacturing

Question 1

What is a JIT system?

Answer 1

• Aim to meet orders quickly, at right quantity and quality with minimum wastage
• Highly dependent on CAD/CAD, allows manufacturers to respond quickly when fashions change
• Used in conjunction with Quick Response
• Reduces need for raw materials stock, space, finished good waiting, cuts cost of money tied up in stock
• Automated manufacturing processes, quick, consistent,
• Large retailers, centralised storage depot, easy/efficient to deliver to
• Controlled by barcodes
• Electronic communication, factories can be anywhere, delivered, cut, sewn, delivered in hours
• Retailers receive as and when, no waste when reordering

Question 2

What is a Unit Production System (UPS)?

Answer 2

• Complete unit of production is automatically transported via computer controlled overheard system from station to station
• All parts required loaded onto hanger
• Brought as close to operator as possible, reducing handling of garment
  PResses button when complete, moves it on
• PC used to plan, control, direct flow of work
• Predetermined rate of production
• Each garment tracked with QC code, cost, time efficient,
• 40 styles at same time, labour costs reduced
• High quality, expensive, specialist training required

Question 3

What is a progressive bundle system?

Answer 3

• Assembly line production, large quantities
• Machines in continuous use, expensive, specialised
• Operator skills are specific, each does only one part
• Identical products produced quickly, boring for workers
• Reduces time and costs but changing line ages long time so not used for high fashion products
• Very stable output, hold ups easily absorbed because of high quantities
• Versatile and efficient when properly managed

Question 4

What is a Section/Process System?

Answer 4

• Operators specialise in one major component: pre assemble, front, back, lining, main assemble etc
• Very efficient for producing variety of styles in reasonable quantities

Question 5

What is one off production?

Answer 5

• Only 1 item made
• High skilled, expert worker/team
• Wedding dresses, haute couture
• Versatile machinery needed
• Complicated, detailed products
• High quality, expensive
• Takes long time, labour intensive

Question 6

What is Batch production?

Answer 6

• Specific number made, each batch can be repeated
• Reasonable skill for workers
• High street fashion items
• Flexible, easily changed, variety of styles
• Lower production costs, staff can be trained
• Equipment needs to be restarted after a production run. losing time
• Stock needs to be stored

Question 7

What is Mass production/continuous flow?

Answer 7

• Production of identical, simple textiles, 24/7
• Highly automated, uninterrupted
• Fabric, thread
• Low cost, small workforce
• Expensive to shut down and restart production if there is a problem
• Can only produce simple products

Question 8

What is Production Planning and Control?

Answer 8

• Helps manufacturers to remain competitive
• In the current market, need more styles, smaller orders and shorter lead times
• Plan movements between warehouse, manufacture, distribution streams
• Constant monitoring of movements

Question 9

Benefits of Production Planning and Control?

Answer 9

• Improved ‘on time’ as constantly monitored
• Fewer production stoppages, lower excess costs
• Improved production performance - lower air freight/late deliveries
• Can respond quickly when requirements change, alternative solutions
• Central storage of all info so better decision making
• Tracks orders throughout supply chain, deal with transport/delivery problems quickly

Question 10

Disadvantages of Production Planning and Control?

Answer 10

Little disadvantages as such obvious commercial gains

• Cost
• Trained personnel
• Constant upgrading, needs to be compatible with all suppliers in chain for greatest efficiency