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Index [TC]² Celebrates 25 Years of Service [TC]² Activity Member Profile - Eton Systems Important Dates

We encourage our readers to participate in Tsunami relief efforts. Visit http://www.apparelandfootwear.org/ for information on ways you can support this cause.

[TC]² Celebrates 25 Years of Service to the Industry

 To commemorate this upcoming milestone, [TC]² will hold an Open House and Reception in conjunction with the Annual Meeting of Members and the Board of Directors on March 29th. More details about the event will be forthcoming, but please mark your calendars now and plan to attend this gala event. We will be inviting our members, associate members, political dignitaries, business associates, faculty fellows, student interns, former staff, and other interested parties to join with us in celebrating our Silver Anniversary.

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[TC]² Activity

 Unit Production Systems

 [TC]²'s demonstration center features two methods for garment production – stand-up, hand-off modular sewing, and the unit production system (UPS). Identified under many names such as material handling system, handling system, and mover, it is most commonly referred to as “The Eton System”, the innovator of the concept.

A study by industrial engineers in Sweden over 30 years ago showed that operators were only spending 20% of their time actually sewing. The rest of the operator's time was spent in handling materials and dealing with personal fatigue issues. To help increase productivity, an overhead conveyor system was designed, containing barcoded hangers. The flexible chain is easily adjusted and can position units for drop-off directly at the needle point. All the pieces of one unit are included in an individual hanger, and each unit can be pinpointed throughout the manufacturing process, simplifying order tracking.

With the UPS system, management's philosophy is changed from “high work-in-process levels are efficient” to “low work-in-process levels allow for Quick Response.” Many steps in assembly can be completed without removing the garment from the hanger system, and the manual handling of bundles from one workplace to the next is eliminated. More than one style can be loaded onto the system, as the computer bar code directs the garment to each workstation for the correct sequence of assembly. Garment pieces kept with one unit eliminate shading issues.

Other system benefits include:

• Increased productivity

• Improved lead times with less work-in-process

• Improved production and quality monitoring

• Improved ergonomics

Transporting by an overhead system keeps the factory floor clear and workstations free of everything except the material needed to complete a specific operation.

Utilizing a single-ply cutter, garment pieces can be loaded directly into the work flow for custom orders.

The system not only can track an individual unit through the production process, but also collects labor costs to impact payroll and help maintain productivity rates. A plug-in module is available to prepare payroll calculations. The software supplies real-time information concerning potential bottlenecks so supervisors can deal quickly with any obstacles. Operators can also track their individual production levels at the work station to measure their performance against goals that have been set.

The UPS system is invaluable in eliminating workplace injuries when dealing with larger, bulky units like bedding, sleeping bags, seat covers and furniture. And, since each unit is barcoded and routed by style, movement of equipment is not required.

Final pressing is minimized as the garments are hanging throughout the manufacturing processing, eliminating creasing and soiling.

Disadvantages include the initial cost of $5,000-$7,000 per computerized station, and that once the system is fixed in position, layout changes are necessary to move it.

Geraldine Williams, a Senior Sewing Specialist at [TC]², states, “After using the traditional bundle system and the UPS, I would not want to go back to a traditional system. Tracking your production is simplified, eliminating pulling coupons from bundles and manually tracking completed work with paper and calculator. Each operator has a confidential log-in so work is easily tracked. No one can use the “wasn't me” defense when quality issues arise.”

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Member Profile

Eton Systems : “The brightest brains hang on Eton”

Eton Systems is the maker of the well known Unit Production System, or UPS, a manufacturing process known throughout the textile industry for its great success stories. First developed as what was called a “workplace system”, today it is popularly referred to as simply the “Eton System”. In essence, the process breaks the traditional “bundle” system to a single unit, transporting all of the pieces of one complete product through the manufacturing process. Automatically moved through the different steps of production, all the components of a garment are carried on an addressable product carrier. With a pair of trousers, for example, you would find each piece or “unit” grouped with its respectable parts: back, front, pockets. Operations are performed at individual workstations, with the operator only handling the part on which she is working, producing a cost-efficient end product.

Eton Systems is more than just the system inventor. They are a company focused on all aspects of product and solution development for the textile industry worldwide. Headquartered in Sweden, the mid 1960's saw cost related problems in the Swedish apparel industry. The management at Eton Shirt Company needed to address inefficiencies in the material-handling procedures. The industry was dealing with high throughput times, unmet delivery demands, and garment workers spending too much valuable time handling and transporting material instead of sewing. Combined with issues like higher wages, technological advances, and changes throughout the industry, Eton stepped forward to take on the challenge of searching for successful solutions.

Inge Davidson, co-owner of the Eton Shirt Company, needed to come up with something to reduce cost and speed up delivery. His ingenious system was simple and effective and efficiency increased immediately. Instead of handling, time could be spent sewing, and production could be more accurately planned. With this, Eton Systems was born. The system offered unparallel flexibility and return on investment. Eton is proud that this remains the same today.

The Eton System is currently used in many industries under the textile umbrella. Automotive interiors see its use, as companies like Volvo use Eton for interior parts of the Volvo S80. Mohawk Industries, a leading American producer of rugs, carpets, and home textile products, use systems to manufacture area rugs and bedspreads. Dowco, a specialized manufacturer of covers for products like boats, motorbikes, and cars uses an Eton System for covers for Harley Davidson, Honda, and Suzuki. Dowco told Eton their system was an excellent method of helping to keep ahead of scheduled deliveries and to remain consistently on budget. Bottom line, Eton helped them stay competitive.

Nobel Prize winners saw the Eton System up close in April 2001. The King of Sweden was there to press the start button on an Eton System that began festivities of the 100th anniversary celebration of the Nobel Prize. Flags were made bearing photos of the more than 700 Nobel Laureates. The exhibition was a success and Eton's contributions were widely noted. A mobile version of the exhibition is touring the world and will make a stop in New York starting mid March 2005.

Headquartered in Sweden with facilities around the world and U.S. headquarters in Alpharetta, GA., the company has installed 2500 systems in 60 countries and remains the undisputed world leader. As this industry changes, reduced cost, increased productivity, fast turn-time and consistent quality becomes paramount and Eton Systems is there to provide support, wherever manufacturers are located worldwide. Combined with those at [TC]² who promote its position in the industry, Eton has become a close partner with a similar mission. “[TC]²'s mission to provide technology solutions and improvements that have a positive impact on the supply chain go hand-in-hand with the benefits Eton offers. We believe that our technology fits with the [TC]² mission and are proud to be associated with [TC]² who also is a daily user of the Eton technology within their manufacturing operation,” confirms Chairman Sven G. Bodell.

For further information on how Eton can work for you, visit www.eton.se .

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Important Dates

January

February

March

For detailed information about industry events, visit www.techexchange.com

Thanks to the techexchange site sponsors Blinco Systems Inc., Gerber Technology and Methods Workshop.

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A Look Ahead

January 25-27 – Colombiatex, Medellin, Colombia

February 14-17 MAGIC Marketplace, Las Vegas Convention Center www.magiconline.com

March 16-18 – Material World, Miami Beach Convention Center

View previous editions of this newsletter

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