Lesson objective – to understand what is meant by one-off, batch and mass production

1. Lesson objective – to understand what is meant by one-off, batch and mass production Textiles – Production Processes

2. Industrial Terms Blanket Order: An order placed on a supplier for a raw material intended to cover the buying company's requirements for a considerable period of time (say, for 6 or 12 months). Continuous Flow Manufacturing - production in which products flow continuously rather than being divided into batches. Production is by rate rather than by work orders Repetitive Manufacturing - Production of discrete units, planned and executed via a schedule, usually at relatively high speeds and volumes. Material tends to move in a sequential flow. e.g. white goods, cars. Batch manufacturing - Intermittent production in standard batch (lot) sizes, determined by market demand, container size, production efficiencies etc. Mass production often involves the assembly of a number of sub-assemblies of individual components. Some parts may be bought from other companies. There is usually some automation of tasks (eg by using Computer Numerical Control machines) and this enables a smaller number of workers to output more products.

3. Job production (one-off production) • this is used when a one-off item is to be made. • the product is made from start to finish by one person or a very small team, all of whom are highly skilled. • the time taken will depend on the design of the garment and the techniques used to create it. For example, a hand-beaded dress will take considerably longer than a chiffon-layered dress. • garments made by job production are unique, of high quality and require a great deal of a worker’s time to complete, therefore they are likely to be expensive.

4. Batch production • suitable for relatively small numbers of identical or similar products. • products made in specific quantities. • produced by a team of workers. • team of workers can make products in less time than one person. • the team share tasks and equipment and may become skilled at one or more of the operations involved; however, work may become repetitive and boring. • allows for flexibility when orders change or market demand changes. • cheaper than job production, because production costs are lower. • Examples of items made in this way are: • All-in-one protective overalls – made in batches of different colours, sizes, patterns, design detail (e.g. number of pockets), collar shapes, cuffs/no cuffs, fastenings (e.g. zip/buttons). • or small batches of different items, for example T-shirts, trousers, tops, sweatshirts, joggers.

5. First production runThe production run is carried out per specification. Processes and operations are tested and monitored closely throughout for potential problems. Quality control is monitored at every stage. fabrics, trimmings and notions are ordered per specification ↓ production pattern is made from basic block ↓ pattern is graded by computer ↓ layplan is created by computer ↓ fabric is spread manually or automatically to required number of plies ↓ fabric is cut ↓ components are stitched using the most appropriate machinery and tools ↓ garment is pressed at various stages of production ↓ garment is finished by hand/machine ↓ completed garments are inspected and compared with specification ↓ garments are packaged ↓ production cycle is repeated according to success of first production run and number of orders received

6. Continuous production This is a method used to manufacture, produce, or process any product without interruption. This method uses an assembly line method, where each operative completes one task in the making of the product. The total task is broken down into sequence and each person does one part. This is a very fast method and allows many products to be made quickly. Employees don’t have to be very skilled as they only complete one part of the task over and over. This can be very boring as a result.

7. In cell production, Workers are organized into multi-skilled teams. Each team is responsible for a particular part of the production process including quality control and health and safety. Each cell is made up of several teams who deliver finished items on to the next cell in the production process. Cell production can lead to efficiency improvements due to increased motivation (team spirit and added responsibility given to cells) and workers sharing their skills and expertise.

8. Each production plan should include the following stages: • The preparation stage details the amount of materials to buy-in, preparation of garment patterns, templates and lay plans. • The processing stage details the fabric spreading, cutting, labelling and bundling of the fabric pieces. • The assembly stage contains instructions for fusing, joining and pressing the separate product parts. • The finishing stage gives instructions for decorative/functional finishing and final pressing. • The packaging stage explains how to label, hang, fold, and cover the product ready for transport to the retailer.

10. 2. Work schedule:A work schedule sets out instructions about the order of assembly, the stitch type, the processes to be used, the time each process will take and the seam allowance. See the example of a work schedule below for a skirt:

11. Computer-numerical control • Computer-aided manufacturing involves the use of CNC machines for printing, cutting, joining and many other textiles processes. CNC-automated machines can repeat processes with accuracy and reliability, and are easily re-programmed when changes to design or production run are needed. The graphic shows some of the uses of CNC machines.