An Optimization Tool for Production Planning: A Case Study in a Textile Industry

Abstract

The textile industry is an important sector of the Brazilian economy, being considered the fifth largest textile industry in the world. To support further growth and development in this sector, this document proposes a process for production analysis through the use of Discrete Event Simulation (DES) and optimization through genetic algorithms. The focus is on production planning for weaving processes and optimization to help make decisions about batch sizing and production scheduling activities. In addition, the correlations between some current technological trends and their implications for the textile industry are also highlighted. Another important contribution of this study is to detail the use of the commercial software Tecnomatix Plant Simulation 13®, to simulate and optimize a production problem by applying genetic algorithms with real production data.

Model based on the Lean Manufacturing methodology to increase the OTIF of a MYPE company in the textile sector

“…In many garment industries, method study is not strictly followed, resulting in higher cost of production and increased lead time of orders to the customer. Along with other work measurement techniques, method study can play a vital role in utilizing resources to improve profit margin and those influences improving company performance [10]. In the same way, various applications of the study of methods require a prior evaluation of the processes that generate production problems, through the techniques of sampling, data collection and analysis.…”

“…Therefore, the garment industries are always trying to improve the production and quality of the garments to stay in the huge competitive market, since the manufacture of garments implies a series of operations carried out in different places by the operators, where these activities must be carried out in a synchronized, planned, and timely manner to achieve the desired on-time production [6][7]. Finally, the project carried out in the company based on the study of methods and times, has allowed an increase in production and a 60% reduction in rework in a textile area with production and reprocessing problems [8][9] [10].…”

Improvement of the production scheduling for the casting line in a manufacturing company

“…There are some reports on the application of scheduling tools to real situations. For example, Ferro et al (2021) apply discrete event simulation software to optimize the production planning of a company in the textile sector in Brazil. Also, Micieta et al (2021) developed a dynamic production scheduling system and they tested it on fictitious data but al-so in data coming from a company that produces railway wagons and bogies.…”

Production management model based on LEAN, TPM, DDMRP, and change management tools to reduce lead times in an SME in the garment manufacturing sector

“…Companies in the textile sector frequently present low efficiency in their production lines, this is due to unexpected stops and unproductive times recorded by the machines, which generates a breach in customer demand [13][14] [15]. Likewise, in the manufacturing industries they register low availability of production equipment, this is caused by the high frequencies of breakdowns and periods of inactivity [16][17] [18].…”

“…Likewise, in the manufacturing industries they register low availability of production equipment, this is caused by the high frequencies of breakdowns and periods of inactivity [16][17] [18]. To reduce this, it is essential to implement systematic procedures of the TPM methodology as a maintenance strategy to improve performance, thus avoiding equipment failure [13][14] [15].…”