Comments on: Batch, UPS and Modular (Batch pt.1)

By: Mike C

Mike C — Thu, 26 Jul 2007 23:46:00 +0000

We’ve contracted with America’s 21st to bring modular sewing into our environment. Their engineer came out and did his initial study and presented their recommendations and ROI for going modular.

The capital cost to convert is high due to conversion costs for our existing machinery and new machinery required to make the mod function. (The cost of the consulting services/training was reasonable – though the entire project is significantly more money than we’ve ever spent at once on anything for any reason.) The payback period is less than 2 years, though we’re doing it for reasons beyond simple cost savings.

We’re looking to start the conversion in September. I’ll update once we do.

By: carissa

carissa — Tue, 10 Jul 2007 04:16:19 +0000

I’m really interested in this topic. One thing about it that I’ve been trying to figure out is – at what point does which setup out pace the other? If you are a one woman show, it seems to me that batching is the way to go. Is modular the thing to do as soon as you get the set up and enough hands to run it? What about jobs where pressing is required during construction? Do you position irons and tables along the “work loop”? It seems to me that when you have few workers, batching is the way to go. You use the same machines for different jobs at the different stages of contruction. It seems like you would need fewer machines. Batching is what I’ve been doing. Although, I do find myself running back and forth a lot. I hope these questions make sense?

By: red_swirl

red_swirl — Thu, 05 Jul 2007 09:00:28 +0000

Somewhat off topic, I’m not soooo sure about your agricultural analogies. I’m certainly no expert, but have you heard of permaculture? If not, you’ll probably enjoy learning about it;)

I guess I’m saying that if you imagine agriculture as ‘fields of wheat as far as the eye can see’ (monoculture), then it’s questionable whether agriculture must/should be like this.

By: Krishna Kumar

Krishna Kumar — Wed, 04 Jul 2007 07:38:43 +0000

Hi Kathleen : I feel the choice of a batching or an UPS or modular depends on the product/market which is catered to by the company. In the case of a high value/Small run orders, it makes sense to go for a modular system where each worker makes most of the garment except areas like cutting. For companies producing large runs, it makes sense to produce using batch/UPS. I feel in most countries in asia, batch system is used since it is very difficult to synchronise (balance) all operations to achieve high efficiencies. Running an UPS requires a high amount of worker training and also a great deal of delegation/empowerment. Most companies which use illiterate people in the labour force find it difficult to practice such concepts. Hence a batch system ensures that a worker has enough work so that his/her utilisation is high. While lean sounds great, implementation is far more difficult if the education levels are lower. In our company, we use a hybrid system. In parts making, we use batches but when it comes to assembly, we break the bundles and move the parts on moveable hangers with each hanger carrying all the parts required for one garment. We have seen improvement in quality and efficiency levels but the true challenge is to implement this right from parts making to the last assembly operation. I agree with you that batching in unavoidable but we should strive to find better ways of improving efficiencies in batching operation. May be the advent of cost effective production tracking technologies in sewing may be of help.

By: Julie K

Julie K — Wed, 04 Jul 2007 03:09:31 +0000

I’m looking forward to the rest of this topic too!

By: Oxanna

Oxanna — Tue, 03 Jul 2007 06:33:08 +0000

Hmm. Interesting, as I have just been considering how I would go about sewing purses as a one-woman, one-machine team. For this situation, I think a modular method would waste my time. I would have to sew, press, sew, etc., and perhaps change feet and/or thread, depending on the project. This is where batching comes in – I can cut 10 purses, sew them, press them, etc., and do it all without as much handling. So for an individual sewer *on one machine*, this is where it comes in handy. Now, if I had several machines all set up for each step, it might be different. (I’d still have to move from machine to machine and adjust my thinking to a “new” process, which might slow me down, IMHO.) In a factory, which is a multi-sewer, multi-machine operation, however, modular might be better. I eagerly await the rest of the entries! (Thank you!)