Abstract:
Ready-made garment manufacturing industries are characterized by high variability of
the processing times, short product life cycle and huge number of employed resources
which contribute to low productivity. Thereby, optimal garment assembly line design is
very crucial for achieving high productivity, increasing line efficiency and improving
decision making at both levels of production planning. Assembly line design problem has
gained attention of many researchers in the past years whereby a number of researches
have been done on garment assembly line balancing problem with simulation technique.
However, very few have used simulation-based optimization technique to address the
design problem. The main objective of study was to design an optimal trouser assembly
line with the parameters’ settings that maximizes the production throughput. Specifically,
the study aimed to analyze current-state of the existing trouser assembly line and develop
its simulation model, to generate design alternatives, and to determine the global optimal
design alternative. The current-state of existing garment production facility was analyzed
using industrial engineering tools which include brainstorming, fishbone diagram, ABC
analysis, process mapping, and time study. Then, the discrete event simulation model of
the trouser assembly line was developed using Arena simulation software and was
validated using one-sample T-test. The trouser assembly line simulation model was
accepted at T-value of -0.20 and P-value of 0.842. Sixteen design alternatives were
generated by performing experiments on the design points derived from the design of
experiment and the metamodel was developed using liner regression method. The
metamodel was validated using significant test at alpha value 0.05 and the best setting
was adopted as the initial solution for the optimization process. Metaheuristic
optimization was performed on the simulation metamodel with the help of OptQuest for
Arena to search for the global best design alternative. The effects of bundle size, job
release policy, task assignment pattern, number of machines and number of helpers on
the production throughput were analyzed. Only two factors; machine numbers and helper
numbers and their interaction have significant effect on the throughput. The comparison
with the existing trouser assembly line design was made based on the production
throughput. The result shows 28.63% increase in the throughput for the trouser assembly
line at metamodel design and the overall increase of 53.63% for the optimal design.
Consequently, the production efficiency increased to 79.75% and 95.25% at metamodel
and optimal design stages, respectively. From the results of the study, it was concluded
that simulation-based optimization via design of experiment is suitable for giving an
insight of garment assembly line and achieving its optimal design. In the further study,
simulation models of garment assembly line can be developed by considering other
design parameters which include machines failure and line supervisor functions. In
addition, further study can be done with different approaches such as using machine
learning and more complex experimental design for developing the metamodels.