clump system

8/13/2019 Clump System

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BY- ANU MAHTO

PRIYANKA SINGH

SAMIRAN HAZARIKA


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In clump system ,a worker collects a clump ofmaterials from the worktable and carries out the firstoperation. After he has completed his part of thework, he returns it to the table. A worker for thesecond operation then continues the work and so on.

The process is ' collection - work -return' continuesuntil the whole garment has been assembled.

It has the same characteristics as the conventionalbundle system


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With this system, sewing machines are arranged in lines.The work flows from the central (store) area to the firstmachine, from the first machine back to the store, andthen on to the next machine, and so forth.

A distributor stationed at the store is responsible forreceiving and dispatching the work

STORE

OPERATOR


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In Clump system , product is manufacturedsection by section with the component unitssewn together at end of manufacturing process.

A clump bundle contains only a single part of thegarment such as sleeve, body, cuff or collar. Etc.

that means this system not only divide the work,but also divide up the garment. Machines of similar operations are clubbed

together instead of spreading over in all lines.For example, when a mans formal shirt is being

made in a section layout collars, cuffs andsleeves are in the preparatory sections and thensend to the assembly section.


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Specific quantity of parts in the bundle isdetermined by number of fabric plies andweight of bundle.

Operators of specialized skills areindependently working at own pace and paidby piece rates.


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The system is flexible, as it can cope with frequent style changes.

Absenteeism and machine breakdown problems will not causeserious problems., as the controller can control the amount of workreceived and dispatched

The system is easy to operate and supervise.

Specialization and rhythm of operation increase productivity.

As the WIP is high in this system, this is stable system.

It is easier to obtain a uniform level of quality, as the controller cancheck the quality control.

The labor cost is less compared with individual system.


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It requires excessive handling of the materials by the operators, asthey have to carry their work back to the central inventory.Operators who are compensated by piece rates become extremelyefficient at one operation and may not be willing to learn a newoperation because it reduces their efficiency and earnings.

It is difficult to control the inventory.It is difficult to see the work in progress at the various stages ofmanufacture.High level of WIP extends throughput timeEngineering of work places is difficult because machines are arrangedin the limited capacity.

High level of work-in-progress.Large storage space is required to cope with the large volume ofwork-in-progress


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The system is used in industries where there

are frequent changes in garment style but alow level of managerial skill.

This system is very efficient for producing avariety of styles in reasonable quantities.

Orders in low to medium volume.


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System attributes roduction systemsClump system Progressive

systemModular system

Work flow push push pull

Method ofretrieval to work

station

Brought tooperator or self

retrieved byoperator fromstore

Brought tooperator from

operator by cartor conveyor

Hand off

WIP inventory High level( racksor carts of

bundles)

Moderate level(enough to

balance the lines)

Zero to minimal

Number of taskper operator

Single task Single task Multiple task

Interactionbetween operators

No teamwork No teamwork Teamwork

Difference from other manufacturing system


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http://ojs.cnr.ncsu.edu www.indiantextilejournal.com

www.onlineclothingstudy.com

www.monozukuri.co.in
http://ojs.cnr.ncsu.edu/http://www.indiantextilejournal.com/http://www.onlineclothingstudy.com/http://www.monozukuri.co.in/http://www.monozukuri.co.in/http://www.onlineclothingstudy.com/http://www.indiantextilejournal.com/http://ojs.cnr.ncsu.edu/


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