A complex garment assembly line balancing using simulation‐based optimization. Issue 11 (3rd September 2020)

• Record Type: Journal Article
• Authors: Bongomin, Ocident; Mwasiagi, Josphat Igadwa; Nganyi, Eric Oyondi; Nibikora, Ildephonse
• Is Part Of: Engineering reports. Volume 2:Issue 11(2020)
• Page Start: n/a
• Page End: n/a
• Publication Date: 2020-09-03
• Subjects: assembly line balancing -- Arena software -- discrete event simulation -- OptQuest optimization -- simulation modeling; Engineering -- Periodicals; Computer science -- Periodicals; 620.005
• DOI: 10.1002/eng2.12258
• Languages: English
• ISSNs: 2577-8196

Abstract

Abstract: 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. Abstract : 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 a 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 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.