Design of a Footwear Assembly Line Using Simulation-based ALNS

Dang, Quang-Vinh; Pham, Khoa

doi:10.1016/j.procir.2016.01.140

Cited by 20 publications

(12 citation statements)

References 17 publications

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“…As shown, 65 trouser assembly line tasks were assigned in 39 workstations with total workstations time of 41.763 minutes and total idle time of 33.117 minutes. The idle time for workstations number 5,6,8,10,19,21,24,26,27,28,29,33,34,36,37,38, and 39 remained very high because of the restrictions on the resource (machine type and helpers) and the precedence relations. The precedence diagram illustrating the relations between 65 tasks in 39 workstations was presented as shown in Figure 5.…”

Section: Ranked Positional Weight Line Balancing For Scenariomentioning

confidence: 99%

“…9 Assembly line design problem consists of grouping and assigning a given set of tasks to a number of workstations so as to reduce idle time, labor cost, and maximize the throughput as well as improve line efficiency without violating the number of precedence constraints. 10,11 This problem is also known as the assembly line balancing problem. 12 Assembly line balancing problems are among the well-known problems in manufacturing systems that belong to non-polynomial (NP)-hard class of problems 13 or complex combinatorial problem.…”

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confidence: 99%

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Improvement of garment assembly line efficiency using line balancing technique

Bongomin

Mwasiagi

Nganyi

et al. 2020

Engineering Reports

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The current competitiveness of garment manufacturing industries is highly dependent on ability to improve efficiency and effectiveness of resource utilization through proper application of industrial engineering techniques such as line balancing and time study. However, very few apparel industries have comprehended industrial engineering function due to little knowledge on practical application of industrial engineering techniques. The present study aimed at balancing a trouser assembly line using the ranked positional weight technique to increase the line efficiency as well as minimize the number of workstations without violating the constraints: precedence relations, cycle time, and resource type. The empirical study was conducted at Southern Range Nyanza Limited (NYTIL) garment manufacturing facility to demonstrate the practical application of ranked positional weight line balancing technique. Results showed that ranked positional weight method is suitable only for assembly line balancing with no constraint on the resource. However, most complex garment assembly lines consist of a number of different machine types rendering ranked positional weight method practically ineffective for improving line efficiency of a complex garment assembly line. Therefore, profound line balancing using simulation-based optimization to improve the line efficiency of complex garment assembly line should be investigated. K E Y W O R D S assembly line, heuristic line balancing, line efficiency, performance indicators, ranked positional weight, resource constraints

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Section: Ranked Positional Weight Line Balancing For Scenariomentioning

confidence: 99%

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confidence: 99%

Improvement of garment assembly line efficiency using line balancing technique

Bongomin

Mwasiagi

Nganyi

et al. 2020

Engineering Reports

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“…Footwear producing companies gain the competitive advantage by their ability to improve the effectiveness and efficiency of resources by waste elimination from the processes (Dang & Pham, 2016). Footwear production is consisted of three sections i.e.…”

Section: Introduction and Literaturementioning

confidence: 99%

Increasing performance of footwear stitching line by installation of auto-trim stitching machines

Kalwar¹,

Khan

2020

J APPL RES TECH ENG

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<p class="Abstract">Industries need to innovate their processes and machines on the advent of new technology in the market especially when there is the matter of line performance, cost and process efficiency. Stitching in the footwear is considered as the bottleneck of the production because of the variability of operations in the different articles (shoes). In this regard, such operations which remains constant (i.e. thread cutting after the stitching operation is complete on the specific footwear component) are required to be automated so that the time and cost can be saved. In the case company, stitching machines don`t cut the thread automatically after the completion of operation on the shoe component. On the same time, such stitching machines are available in the market which cut the thread automatically when the operation is completed. Before, purchasing those machines, it was needed to prepare the feasibility of the investment and its impact on the performance, cost effectiveness and overall line efficiency. One of the latest machines was brought for trial in the case company and the stitching operations were performed on both machines (existing and new machine) so that the difference in the performance can be calculated. Time of the performed operation was recorded by the help of stopwatch, amperes of the motors of existing machines were checked by the help of ampere meter. The data was put into MS excel and various formulae were applied in the spreadsheet to prepare the feasibility. It was concluded that after the installation of 10 post bed single needle stitching machines and 2 post bed double needle stitching machines, the production will increase by 61 pairs/day; the line efficiency will increase by 12% and Rs.8/pair will be saved.</p>

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“…The balancing of assembly lines is an important issue in manufacturing engineering, management, and control. [5][6][7] However, assembly line balancing is a very complex phenomenon which has been dubbed as a nondeterministic polynomial (NP) hard problem or complex combinatorial problem. 8,9 Despite the fact that research on assembly line balancing dates back to more than a century, it is still of interest to many researchers.…”

Section: Introductionmentioning

confidence: 99%

A complex garment assembly line balancing using simulation‐based optimization

Bongomin

Mwasiagi

Nganyi

et al. 2020

Engineering Reports

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The nascent wave of disruptive competition in the current business environment brought about by the fourth industrial revolution (Fashion 4.0 or Apparel 4.0) is enormous. Therefore, it is important for the apparel industry to be flexible enough to respond quickly to the unstable customers' demand through continuous improvement of their process efficiency and productivity. This study proposed assembly line balancing problem (ALBP) for complex garment assembly line using simulation-based optimization under stochastic task times. The proposed ALBP solution approach aimed at minimizing the cycle time for a given number of workstations with consideration of constraints on number of resources, precedence relations, and resource types. The empirical study was conducted at Southern Range Nyanza Limited (NYTIL) garment facility and a complex trouser assembly line with 69 workstations was considered. The discrete event simulation of the trouser assembly line was developed using Arena simulation software. The local optimal solution was obtained from simulation experiments which was adopted for the optimization process. The OptQuest tool was used to solve a single objective optimization with discrete control values. The results showed that the average throughput increased by 30% for local optimal line balancing and 55% for global optimal line balancing. Consequently, the cycle time reduced by 23% and 36%, respectively.

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Design of a Footwear Assembly Line Using Simulation-based ALNS

Cited by 20 publications

References 17 publications

Improvement of garment assembly line efficiency using line balancing technique

Improvement of garment assembly line efficiency using line balancing technique

Increasing performance of footwear stitching line by installation of auto-trim stitching machines

A complex garment assembly line balancing using simulation‐based optimization

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