Which production system is better - A Conventional line Or A Modular line?

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As I have explained earlier in the article “Garment Production Systems” that each production system has benefits over others depending on order size, product type, technology level and skill level of the operators. When it comes lean manufacturing system in apparel making, factories start implementing modular system whatever product they might produce. It is true that in Lean environment modular line is most effective than a conventional line if modular line is run scientific way.


To support the above statement, I will take example of Madura Clothing’s shirt line. Recently in a conference Mr. Lal, Head Manufacturing, Madura Clothing, presented a case of the Shirt line. They have both conventional line and Modular line in a same floor. As per his presentation, in Modular line they produce 14.3% more shirts with 23% less operators comparing to the conventional line. Secondly, the labor productivity (operator only) of the Modular line is 48.6% higher than conventional line.

In the following table comparison has been show with other parameters.



Conventional Line
Modular Line
Total of 2 Modular line
Improvements
1
Production/day
700
400
800
14.3%  Higher
2
No. of Operators
52
20
40
23.1% Less
3
35
70
70
Higher
4
Throughput time (Theoretical)
1820
1400
1400
Less
5
Effective Throughput time
1870
700
700
Less
6
Labor Productivity
13.5

20
48.6% Higher


Related Articles
    Comparison between Progressive Bundle system (PBS) and Unit production system (UPS) 
    Apparel Manufacturing - An Overview
    How to calculate SAM of a garment
    Different types of garment production systems

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Online Clothing Study: Which production system is better - A Conventional line Or A Modular line?
Which production system is better - A Conventional line Or A Modular line?
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