Benefits of Single-Piece Flow Production System

Single-Piece Flow system is one of the many garment production systems. In Single-Piece Flow system only one garment is processed at a time through various operations in a sewing line. This production system is also known as one-piece flow system. A single-Piece flow system is considered as a part of lean manufacturing system. So, lean philosophy is applied when one uses single-piece flow system.

Like others production systems this production system has number of merits and demerits. In this article I will explain merits of the Single-Piece Flow production system related to garment industry. Benefits explained in the following are irrespective of a lean manufacturing.

Benefits of the Single-Piece Flow systems are as followings:

Reduces throughput time - Time required coming out pieces from the production line after feeding is quicker than traditional progressive bundle system. Reduced throughput time of an order has many other subsequent benefits.
Quicker response – This system reduces overall lead time for an order processing. Factories can response to market demands quickly.

Faster money circulation - In this system no much inventory is stored and production lead time time is less. Factory doesn't need to block money in lot of material purchasing, transportation and warehouse.

Easier to change product - Setting up a line for new order or a new style is easier in one-piece flow system. Style changeover time is also less compared to progressive bundle system as there in no much WIP in the production line.

Improves garment stitch quality - Due to less throughput time, faults are detected quickly and feedback on stitching quality is given faster for preventive action. Also in lean manufacturing one-piece flow system quality is in-build. This means each operator is responsible for checking quality of the work. No defects passed to the following operations. This way defect generation at machines can be reduced. Secondly when there are fewer defects in garments, quality checker checks a garment in less time compared to exiting production system.

Reduces rework level – Fewer defects mean less rework.

Better quality control – In this system, as any fault is detected within minute of its occurrence garment quality can be managed in a better way.

Improves labor productivity – Productivity in a single-piece flow system is higher than a batch production. Reason – Non-value added activities are eliminated in one-piece flow system. Thus operator can produce more standard hours in the given time.

Better line balancing –Equal work distribution to operators can be done by clubbing low work content jobs. As a result minimum bottlenecks exist in the line.

It is considered that cost of manufacturing for smaller quantity order is less in a single bundle system in comparison to progressive bundle system.



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Online Clothing Study: Benefits of Single-Piece Flow Production System
Benefits of Single-Piece Flow Production System
In garment manufacturing, single-piece production system has many benefits over assembly line or batch system. Read this article to know various merits of one-piece flow system.
Online Clothing Study
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