In the textile industry, garment manufacturing contains four major processes containing cutting, sewing, finishing, and packaging. Sewing is the most crucial and intricate section, dealing with a large number of varied operations. A successful sewing process needs to be optimized regarding different factors, including time, sewing equipment, and skilled workers. Assembly line flow is combined by a set of operations with a particular sequence. The utmost importance of all garment industry is to arrange the workstations to minimize the number of employees in order to produce at the best productive rate with the most reasonable cost, shortest time, and satisfying quality. In most garment factories, the production lines are balanced using the empirical judgment of the line managers. For the whole process the data of production time at each step, labor productivity, proper choices of equipment were always needed to calculate line efficiency. As far as the issue is concerned, there has not been an academically sewing process analyzing software providing adequate data of sewing motions and sewing time as the credible input for the line balancing tasks. Towards this goal, this paper presents the results of research on optimizing academically self-built software to analyze the sewing process of knitted products applied to industrial production using Java programming language on Google tools. The results achieved by the software are not only to analyze sewing products and the technological sewing process, calculate the sewing time on the machine but also analyze the sewing activities of workers into manipulations, movements, and motions to calculate the preparation time for two typical knitted products, namely, Polo-Shirt and T-Shirt with the case studies at General Textile Garment Joint Stock Company Hanoi and Star Fashion Company Limited.
Line balancing is always a big problem appearing in industrial production. Manual balancing of industrial sewing products takes a long time to give results, which depends on the experience of the sewing line manager, moreover, the efficiency is not necessarily optimal. Digital conversion will help find a solution to balance the sewing line more quickly, accurately, and optimally. This study presents the statements of the problem of balancing knitted garment lines in the industry with the line balancing process according to the method of Hanoi University of Science and Technology (HUST) and BSL-HUST-1 software, which is the software designed and built by our research group. For the balancing calculation, three groups of input data were defined for the comparison of balancing efficiency among the HUST method, the software method, and the method used traditionally by the companies. The line's capacity is determined as the total production amount in a shift, and the shift time is figured accordingly following each factory's rules. The total number of workers is an essential factor. Also, the cycle time is one of the important factors for balancing the sewing line.
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