A Comparative Study Between Unit Production System and Progressive Bundle System in Apparel Production

Abstract

The apparel manufacturing industry in Bangladesh experiences dynamic inefficiencies in its production system, which are interconnected with various unforeseen events. These inefficiencies hurt productivity, increase costs, and lead to increased rates of defects. This article conducts a comparative analysis between two predominant production systems, namely the progressive bundle system (PBS) and the unit production system (UPS). The study involved an examination of critical aspects such as material handling, floor space utilization, standard minute value (SMV), output, productivity per operator, product quality, efficiency, manpower allocation, and work-in-progress. The overall performance and suitability of these systems are evaluated through a quantitative analysis of primary data. To carry out this study, we have collected data from the operation breakdown of men's hoodie jackets, which is a critical product in the apparel industry. The results have indicated that the unit production system outperforms the progressive bundle system. We also demonstrate that the results may vary from one factory to another, as well as from style to style. Indeed, the results can depend on the skills and expertise of the workforce.