Jan 17, 2017

Modular Production team in the Apparel Industry

it is well standard that manufacturers of customer goods all over the world are facing major new demands, as well as shorter product life-cycles and rising competition. In response, companies are reorganization and moving away from traditional process-center work practices in favors of concurrent engineering methods. 
In exacting, design for manufacture has gained common recognition as a means of reducing production costs and lead times. However, the optimal design for manufacture is not easy to achieve using current-day work organization and business structures. So we have to build a Modular Production team in the Apparel Industry with Procedures, Responsibility, Rules, and authorities.



Team Responsibility

  • Team is responsible to report of Production and Quality to the Leader.
  • Team work together to achieve objectives (ensure quality and meeting cycle time / tackt time, as determined by the management. (Team must control their absenteeism level, productivity and quality in order to achieve their incentive).
  • Team must perform a complete task as described in their operations assignments unless is required by the team leader to support some other areas.
  • Incentive Pay is a result of group performance (quality, attendance and productivity).
  • Team must monitor all keys performance as determined by the management.
  • Team is responsible in sustaining 5S concept in all time.
  • Team is responsible to deliver only acceptable quality Garments. 

     Team Rules 

  • Scissors are attached to the sewing machine, the wrist or to the table.
  • Team members are not allowed to remove the scissors off the sewing machine, the wrist or the table. If they do, scissors must be kept in designated area.
  • Threads must be trimmed after completing assigned operation by workers.
  • No one is allowed to walk with the scissor or keeping it in the pocket.
  • The Final checkers (Q.C.’s) are not allowed to carry a scissor with them or to fix a scissor in to the table. Long hanging thread is considered as defect and is returned to the SMO to trim.
     In case of Quality problems, refer to quality at the source.


    Management Policy:

  1. The management is responsible of assuring manufacturing staffs comply with all roles and responsibility described in this manual.
  2. The management is responsible for truly empowering the team. 

   Supervisor Role:

  •  The supervisor is in charge of planning the production of the teams.
  • The supervisor must provide technical assistance to the team under the request of the leader.
  • The supervisor has the right to track the production amongst the teams without interfering with the members. 
  • The supervisor has the right to verify the quality of finished products. In case of discrepancy, communication is limited with the leader.
  • The supervisor must conduct 5 minutes meeting with the leader about to assigning the task to the team for capability assurance by the team.
  • The supervisor must ensure all requirements related to item no. 1.8  are prepared and delivered to the team.
  • The supervisor is responsible in communicating the requirements of the team to the management.

 Team Leader Role:

  • The leader is the principal contact of the team with the management.
  • The leader is the responsible to monitor the quality of first and last processes and the output. (Quality is the team responsibility) 
  • The leader is in charge of the environment within the cell.
  • The leader is responsible to maintain the discipline of the team.
  • The leader is responsible to ensure the accuracy of reported data.
  • The leader provides help and assistance to the team members.
  • The leader is in charge of members assignments.

Team Authority:

The team has the rights to refuse, stop any production due to the following issues:
  • Nonadequate Machinery
  • Defected cuts pieces from the Cutting Department.
  • Size Labels and different shades Mixture
  • Missing information, materials and tools as described in item no. 1.8 .


The team has the rights to request a time study or follow-ups for certain operations where there is doubt of time accuracy (SMV) related to the target.

Meeting Structure:

Meeting must not be longer than 5 minutes and must be held inside the cell.

  • Assignments meeting at initial start up of new order and quality standards distribution. (Occasional)
  • Troubleshooting related to Quality problems when reject rate is out of order. (Occasional)
  • Internal attitude problems of module team (involves only leader and the concerned operator). (Occasional)
  • 3 Minutes at end of the day for “SHINE” session. (Daily)
  • Performance meeting for 10 minutes to evaluate the overall performance of the week. (Weekly) 

Requirements prior to initial orders start-up:

Before start the initial sewing, modular team should receive the following documents and items:

  • Trims card (original samples),
  • P.O. Sheets of the new style,
  • All Original Size labels,
  • All Original Hang Tags,
  • Green seal sample including hang tags and size labels approved by the Buyers/Merchandiser,
  • Measurement spec,
  • Critical Points instruction,
  • New quality record papers,
  • Sketch of measurement,
  • Operations bulletin with quality standards,
  • Work Load Orders (productivity target, Pitch time, days available, etc..)
  • Checklist orders quantity,
  • Pattern of the orders sizes and different parts,
  • Scrap fabric from the cutting room (same type as the style) for machineries adjustment,

        Absenteeism coverage:

No strange labor would be added in case of absenteeism. No any other worker will added to the Module team incase of absenteeism. Absenteeism must be covered using the bump-Jump system of which an operator moves from her station to another station on the basis of the operations sequences till reaching another operator then her or him drops the bundle and return back to its original station. In case of original station is occupied by another operator (A), the replacement operator (A) will leave the station immediately and returns back to her or his original station or till reach another bundle through the process.  However, if the factory has pool of special runners (multi-skilled jumpers) leader has the right to request temporarily replacement to cover up the absenteeism. For this purpose, leader communicates with the supervisor. 

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