Registering your cotton apparel manufacturing business on TEXchange Global can lead to a significant increase in the demand for cotton fabric online. However, the main objective of any cotton garment production company like yours is to produce high-quality products at a lower cost and in less time. Therefore, there’s increased pressure on apparel brands and textile manufacturing companies. They have to complete production in terms of cost, delivery time, and after-sales service.
As you know, the textile industry is going through enormous changes. In order to succeed in the competitive global market, cotton manufacturers and wholesale fabric suppliers online in India must create adaptable production systems. These systems should respond to cotton buyers quickly and efficiently while also minimizing production and product costs. In this blog, we will discuss the textile manufacturing industry’s production organization system for businesses that are new to textile and garment manufacturing and supplying.
Production Organization Solutions that Manufacturers can Adopt to Address Increased Demand for Cotton Fabric Material Online
Within the garment manufacturing industry, three main production systems exist: The Synchronized or Straight-Line system, the Section or Process system, and the Progressive Bundle or Batch system.
This system is suitable for businesses that run large batches of production or mass production. In the straight-line workflow method, a synchronized sequence of workstations is used, with each station assigned an equal amount of time. To achieve this, every step involved in product assembly needs to be analyzed carefully and distributed in a balanced manner across the available workstations. Operators perform the same repetitive operation on successive garment components. It is important to have detailed work plans to ensure the line is balanced and efficient.
Benefits of Synchronized System for Fabric Producers
- Shortens the distance between two workstations
- Helps manufacturer plan production time accurately
- Minimizes work in process (WIP)
- Production process is visible, enabling the manufacturer to predict the quantity and capacity
Although this approach has its benefits, there are also some drawbacks to consider. For instance, altering the design can be quite costly, and manufacturers must engage in extensive planning beforehand. Additionally, production issues and employee absences can disrupt the process.
The Section system is tailored for manufacturers who frequently change their designs and produce a limited volume of each product style. It optimizes the manufacturing process with a sewing room that has several specialized sections, each responsible for assembling a major component of the garment.
The sections are arranged in a way that ensures a seamless and efficient workflow, with each output end placed near the subsequent input end that requires that specific component. This arrangement minimizes unnecessary movement and transportation of materials, reduces production delays, and enables quick adaptation to design changes.
This enhanced spatial arrangement and workflow allow manufacturers to respond promptly to evolving design demands while producing diverse garment styles with high-quality standards.
Benefits of Section System for Manufacturers
- Labors with limited experience, such as interns and trainees, can work here
- Style and personnel changes are allowed with little influence or modification
- Labor cost is low, and productivity is high
It’s worth noting that this system does have its limitations. One major requirement is a significant amount of space in order to install the entire system. Additionally, manufacturers are unable to accurately determine production time, which can lead to longer throughput times. There’s also the potential for increased inventory costs due to work in progress and lot mixing up, and size and shade variations, hampering apparel quality and production.
Progressive Bundle System
The progressive bundle system is a combination of the straight-line and section systems. This method involves organizing machines and workers into sections based on their specific functions, such as producing sub-components like collars, sleeves, pockets, and joining. The workload of each section is balanced according to the time required for each sub-function.
The bundles and a line system provide an ideal solution for manufacturers facing frequent design changes, small production batches, and tight delivery schedules. The system allows for efficient handling of diverse apparel needs, as workers focus on specialized tasks within their sections, leading to smoother production transitions.
With its adaptable and streamlined workflow, this method allows manufacturers to quickly respond to design changes, efficiently produce small quantities of each style, and meet tight delivery schedules. The progressive bundle system optimizes production processes, enhancing productivity, flexibility, and the ability to effectively meet diverse customer demands.
Benefits of Progressive System for Textile Manufacturing Companies
Apart from all the combined benefits of the first two systems, the progressive bundle system allows manufacturers to produce superior quality products as each component is separately checked for quality during operation.
Since the bundles are moved from one process step to another, shade, size variation, and lot mixing-up don’t happen.
Manufacturers can easily implement stringent production and quality control in the production system, improving productivity, delivery, and ultimately more inquiries from wholesale fabric suppliers online in India.
Disadvantages of Progressive Bundle System
Despite all the advantages, the system has quite a few drawbacks, including:
- Difficulty in line balancing. To balance the line, utility operators and batch shuttles are needed
- High maintenance of machinery and equipment
- Require thorough production planning with proper layout, as poor planning can lead to labor turnover, poor product quality, and less production.
- This system is not efficient for manufacturers who need to produce more styles in less quantity
There are modern methods of production organization for textile manufacturers, such as Just-in-Time, Total Quality Management and Lean Production, and Toyota Production Systems, that can help many new entrants. Damodar Menon International, India’s largest and oldest textile trading company with 60 years of experience, discusses these systems in their blog. Please check it out here.
Efficient and advanced organization systems are crucial in the cotton garment manufacturing industry. These systems help boost productivity, reduce costs, increase cotton fabric online sales, and meet the needs of cotton buyers. Implementing effective approaches such as lean manufacturing, computer-aided design, and automated production processes can significantly enhance competitiveness and efficiency in the industry. TEXchange Global is a great example of how streamlined online sales can benefit manufacturers and wholesalers.