Bundling and ticketing

Bundling" is the process of disassembling the stacked

and cut pieces and reassembling them in production
lots grouped by garment unit, colour dye lot, and
number of garments.
Manufacturers use a variety of bundling methods
depending upon their needs.

Four basic systems being the most common among

manufacturers.
Group bundling
Progressive bundling
Item bundling
Unit production system (UPS)
Modular or "team based

1. Progressive Bundle System (PBS)

Also Called Material Handling System.
As name implies the bundle of garment parts move
from operation to operation.
Traditional Production system.
Widely used by apparel manufacturers for several
decades and still today.
80% apparel manufacturers use the Bundle system
(PBS).

PBS Workflow
Bundles consist of garment parts needed to complete a specific operation
(e.g an operation bundle for pocket setting might include shirt fronts and
pockets to b stitched together.
Some firms operate with a standard bundle size, while other vary bundle
sizes acc. to size of pieces in bundle and operation to b completed.
Bundles are assembled in the cutting room, where cut parts are matched
up with corresponding parts and bundle tickets.
Workers (labour) transport and move Bundles of cut parts to sewing room
via trollies.
Operator scheduled to complete the operation and perform same
operation on all pieces in the bundle, retie the bundle, remove Bundle
ticket and move bundle for next operation.

Advantages of PBS
Labor of all levels ie unskilled, skilled, semi skilled
labors are involved. Small simple operations.
Quantity of each operation is checked during every
single operation thus quality is good.
Due to bundle system, less chance of mixing up of
partsthus less confusion.
Bundle tracking is possible, so identifying and solving
problems become easy.
Effective production control system and Quality control
system.

2. Unit Production System (UPS)

A Unit Production System is a type of layout that uses an overhead
transporter system to move garment components from work
station to work station for assembly.
In UPS, there are hangers. One hanger have multiple clips
containing all parts of the single garment.
All parts for the single garment are advanced through stitching
line together by means of hanging carrier that moves along an
overhead conveyor.
Hanging carrier can be moved manually by the operator using
button after completion of single operation or By computerized
system that move the conveyor after a specific fed throughput
time.

Advantages of UPS
Bundle Handling completely eliminated.
The time involved in the pick-up and disposal is reduced to
minimum.
Output is automatically recorded, eliminates the operator to
register the work.
The computerized system automatically balance the work
between stations.
Improved lead times-less work in process.
Improved space utilization (more machines can be adjusted)

Advantages of UPS (Cont.)

Increased Productivity.
Throughput time can be drastically reduced.
Indirect labor costs are reduced (by elimination of
bundle handling and requiring fewer supervisors)
Improved production and quality.

Dis-advantages of UPS
Unit Production system requires high investment.
Proper planning is required to be effective.
Highly expensive-buying equipment and cost of
installing.
Specialized training for the system.

3. Modular Production System

A Modular Production System is a contained, manageable work
unit that includes an empowered work team, equipment and
work to be executed.
The number of teams in a plant varies with the size and needs
of the firm and product line.
Usually there are 4-15 labors in one team depending upon the
type of garment to be stitched and skills of labor.
Teams may be used to perform all the operations (whole
garment production) or certain portion of assembly operations.
Team is responsible fro maintaining a smooth work flow,
meeting production goals, quality level.

Bundle ticket
Bundle ticket also known as work or pay control ticket
Originates in either cutting department or the pay-roll
department
Used for pay control as well as production control
process
Can be used for unit flow as well as bundle flow
production systems
All bundle tickets have Two major sections:
One is Returned to payroll control by production supervisory
staff
Second is submitted by the operators

 In sectionalized production system bundle ticket Is

perforated in sections and sub-sections according to the
total number of sub assembly and assembly lines as
well as the number of jobs in them.
Thus two divisions are formed out of the bundle ticket :
Supervisory division
Sub-section which each operator takes

 Each of the supervisory division contains:

a) Serial number of the entire bundle ticket
b) The name of the sub-section, such as sleeve, collar,
front, etc.
c) Style name or number
d) Cutting order number or spreading ticket number
(move ticket number)
e) The date the bundle was compiled in the cutting
department
f) Size, amount, color of the bundle
g) Name of each job in the section and the number of the
operator who did the job, next to each job name, also

 Each of the operators sub-section contains:

a) Name of the job
b) Bundle ticket number
c) The amount, size and color of the bundle
d) The price of job
e) The style name or number
f) The move ticket number controlling the bundle (or the
cutting ticket number)

 There should be only one copy of each bundle ticket

(with the same bundle ticket serial number), otherwise
it would be impossible to prevent payment twice for a
given task.

 The purpose of bundle tickets is to:

o Monitor the progress of each specific garment,
o Ensure that the correct parts are assembled together,
and
o Compensate operators for their work on each garment.

Bundling
Works best for the work station layout which permits the
bundler to sort with
A motion pattern devoid of backtrack or criss-cross
movements
Minimum distance from stack to stack

Manner of folding or superposing the plies in the

bundles should be such that there is
Minimum or no creasing
Minimum or no disarraying of the cut alignment

 Tier stack bins (or boxes) on casters- excellent means

for bundling and transporting cut sections without the
necessity of bundle tying.
The sorted stack should be packed between two plies of
masonite or appropriate cardboard.
Perfect quality and securement can be had by
Making the bundle board slightly larger than the pattern area
Securing the sides of the board with outside latches

Off Loading
Off loading is the process of removing cut parts from the
cutting table, counting, ticketing, and grouping them.
Cut parts are considered work-in-progress inventory and
are counted and tracked through the rest of the
production processes.
This is usually done through bundle tickets that
originate with cutting orders.

 Cut part identification involves identifying and marking parts for

further operations.
Throughout the sewing process, it is essential that each garment
be assembled from parts that have been cut from the same ply of
fabric, which is ensured by shade marking each piece in the lay.
Every piece is ticketed with a style number, size, and ply number.
Shade marking is done prior to bundling.