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Balancing The Shirt Production Line Under Different Operational Constraints Using An Integer Programming Model

Year 2022, Volume: 32 Issue: 4, 353 - 365, 31.12.2022
https://doi.org/10.32710/tekstilvekonfeksiyon.1020866

Abstract

Efficient use of capacity is significant to enable apparel businesses to work cost-effectively and provide timely service to their customers. The increase in assembly-line efficiency is associated with lower operating costs. Therefore, the main purpose of balancing assembly lines is to manufacture products as profitable and as quickly as possible. In this study, we consider a single-model assembly line balancing problem with workforce and machine constraints in the sewing department of an apparel company. We develop an integer programming (IP) model to optimally balance the shirt production line, considering parallel machines in each stage of the line and various operational constraints such as cycle time and precedence constraints, task machine eligibility, the number of operators available. The IP model can either minimize the number of open workstations or both, minimize the number of open workstations and assign tasks in subassembly parts as close to each other as possible. The model has been run under various scenarios using LINGO 15.0 optimization software. Additionally, we have balanced the shirt production line using the Ranked Positional Weight Method (RPWM). The IP model outperforms the RPWM results across all scenarios and finds 33 stations and 86.8% efficiency compared to 38 stations and 75.4% balance efficiency with the RPWM.

References

  • 1Cercioglu H, Ozcan U, Gokcen H, Toklu B. 2009. Paralel Montaj Hattı Dengeleme Problemleri İçin Bir Tavlama Benzetimi Yaklaşımı. Gazi Üniversitesi Mühendislik ve Mimarlık Fakültesi Dergisi 24(2), 331-341.
  • Eryuruk SH, Kalaoglu F, Baskak M. 2008. Assembly Line Balancing in a Clothing Company. Fibres & Textiles in Eastern Europe 16(1), 93-98.
  • Kriengkorakot N, Pianthong N. 2007. The Assembly Line Balancing Problem: Review Articles, KKU Engineering Journal 34(2), 133-140.
  • Kursun S, Kalaoglu F. 2010. Line Balancing by Simulation in a Sewing Line. Tekstil ve Konfeksiyon 20(3), 257-261.
  • Kayar M, Akalin M. 2016. Comparing Heuristic and Simulation Methods Applied to the Apparel Assembly Line Balancing Problem. Fibres & Textiles in Eastern Europe 24(2), 131-137.
  • Unal C, Tunali S, Güner M. 2009. Evaluation of Alternative Line Configurations in Apparel Industry Using Simulation. Textile Research Journal 79(10), 908-916.
  • Unal C, Bilget S. 2021. Examination of Lean Manufacturing Systems by Simulation Technique in Apparel Industry. The Journal of the Textile Institute 112(3), 377-387.
  • Unal C, Demirbas ZA. 2018. Creating an Alternative Production Line by Using a Simulation Technique in Duvet Cover Production. Fibres & Textiles in Eastern Europe 26(4), 8-12.
  • Eryuruk SH, Kalaoglu F, Baskak M. 2011. Assembly Line Balancing by Using Statistical Method in Clothing Production. Tekstil ve Konfeksiyon 21(1), 65-71.
  • Guner M, Yucel O, Unal C. 2013. Applicability of Different Line Balancing Methods in the Production of Apparel. Tekstil ve Konfeksiyon 23(1), 77-84.
  • Karabay G. 2014. A Comparative Study on Designing of a Clothing Assembly Line. Textile and Apparel 24(1), 124-133.
  • Unal C. 2013. A New Line Balancing Algorithm for Manufacturing Cell Transformation in Apparel Industry. Industria Textila 64(3), 155-162.
  • Turkmen A, Yesil Y, Kayar M. 2016. Heuristic Production Line Balancing Problem Solution with MATLAB Software programming. International Journal of Clothing Science and Technology 28(6), 750-779.
  • Jirasirilerd G, Pitakaso R, Sethanan K, Kaewman S, Sirirak W, Kosacka-Olejnik M. 2020. Simple Assembly Line Balancing Problem Type 2 by Variable Neighborhood Strategy Adaptive Search: A Case Study Garment Industry. Journal of Open Innovation: Technology, Market and Complexity 6(21), 1-21.
  • Bongomin O, Mwasiagi JI, Nganyi EO, Nibikora I. 2020. Improvement of Garment Assembly Line Efficiency Using Line Balancing Technique. Engineering Reports 2, 1-18.
  • Kayar M, Akalin M. 2014. A Research on the Effect of Method Study on Production Volume and Assembly Line Efficiency. Tekstil ve Konfeksiyon 24(2), 228-239.
  • Ahmed T, Sakib N, Hridoy RM, Shams AT. 2020. Application of Line Balancing Heuristics for Achieving an Effective Layout: A Case Study. International Journal of Research in Industrial Engineering 9(2), 114–129.
  • Gursoy A. 2012. An Integer Model and a Heuristic Algorithm for the Flexible Line Balancing Problem. Tekstil ve Konfeksiyon 22(1), 58-63.
  • Gursoy A, Gursoy N. 2015. On the Flexibility Constrained Line Balancing Problem in Lean Manufacturing. Tekstil ve Konfeksiyon 25(4), 345-351.
  • Xu H, Xu B, Yan J. 2019. Balancing Apparel Assembly Lines Through Adaptive Ant Colony Optimization. Textile Research Journal 89(18), 3677–3691.
  • Ahmed N, Ador MSH. 2020. Multi-Objective Mixed Model Assembly Line Balancing Using Mixed Integer Linear Programming. American Journal of Industrial Engineering 7(1), 14-25.
  • Helgeson WP, Birnie DP. 1961. Assembly Line Balancing Using the Ranked Positional Weight Technique. Journal of Industrial Engineering, 12(6), 384-398.
  • LINGO. 2015. The Modeling Language and Optimizer. Chicago, Illinois: LINDO Systems Inc.
Year 2022, Volume: 32 Issue: 4, 353 - 365, 31.12.2022
https://doi.org/10.32710/tekstilvekonfeksiyon.1020866

Abstract

References

  • 1Cercioglu H, Ozcan U, Gokcen H, Toklu B. 2009. Paralel Montaj Hattı Dengeleme Problemleri İçin Bir Tavlama Benzetimi Yaklaşımı. Gazi Üniversitesi Mühendislik ve Mimarlık Fakültesi Dergisi 24(2), 331-341.
  • Eryuruk SH, Kalaoglu F, Baskak M. 2008. Assembly Line Balancing in a Clothing Company. Fibres & Textiles in Eastern Europe 16(1), 93-98.
  • Kriengkorakot N, Pianthong N. 2007. The Assembly Line Balancing Problem: Review Articles, KKU Engineering Journal 34(2), 133-140.
  • Kursun S, Kalaoglu F. 2010. Line Balancing by Simulation in a Sewing Line. Tekstil ve Konfeksiyon 20(3), 257-261.
  • Kayar M, Akalin M. 2016. Comparing Heuristic and Simulation Methods Applied to the Apparel Assembly Line Balancing Problem. Fibres & Textiles in Eastern Europe 24(2), 131-137.
  • Unal C, Tunali S, Güner M. 2009. Evaluation of Alternative Line Configurations in Apparel Industry Using Simulation. Textile Research Journal 79(10), 908-916.
  • Unal C, Bilget S. 2021. Examination of Lean Manufacturing Systems by Simulation Technique in Apparel Industry. The Journal of the Textile Institute 112(3), 377-387.
  • Unal C, Demirbas ZA. 2018. Creating an Alternative Production Line by Using a Simulation Technique in Duvet Cover Production. Fibres & Textiles in Eastern Europe 26(4), 8-12.
  • Eryuruk SH, Kalaoglu F, Baskak M. 2011. Assembly Line Balancing by Using Statistical Method in Clothing Production. Tekstil ve Konfeksiyon 21(1), 65-71.
  • Guner M, Yucel O, Unal C. 2013. Applicability of Different Line Balancing Methods in the Production of Apparel. Tekstil ve Konfeksiyon 23(1), 77-84.
  • Karabay G. 2014. A Comparative Study on Designing of a Clothing Assembly Line. Textile and Apparel 24(1), 124-133.
  • Unal C. 2013. A New Line Balancing Algorithm for Manufacturing Cell Transformation in Apparel Industry. Industria Textila 64(3), 155-162.
  • Turkmen A, Yesil Y, Kayar M. 2016. Heuristic Production Line Balancing Problem Solution with MATLAB Software programming. International Journal of Clothing Science and Technology 28(6), 750-779.
  • Jirasirilerd G, Pitakaso R, Sethanan K, Kaewman S, Sirirak W, Kosacka-Olejnik M. 2020. Simple Assembly Line Balancing Problem Type 2 by Variable Neighborhood Strategy Adaptive Search: A Case Study Garment Industry. Journal of Open Innovation: Technology, Market and Complexity 6(21), 1-21.
  • Bongomin O, Mwasiagi JI, Nganyi EO, Nibikora I. 2020. Improvement of Garment Assembly Line Efficiency Using Line Balancing Technique. Engineering Reports 2, 1-18.
  • Kayar M, Akalin M. 2014. A Research on the Effect of Method Study on Production Volume and Assembly Line Efficiency. Tekstil ve Konfeksiyon 24(2), 228-239.
  • Ahmed T, Sakib N, Hridoy RM, Shams AT. 2020. Application of Line Balancing Heuristics for Achieving an Effective Layout: A Case Study. International Journal of Research in Industrial Engineering 9(2), 114–129.
  • Gursoy A. 2012. An Integer Model and a Heuristic Algorithm for the Flexible Line Balancing Problem. Tekstil ve Konfeksiyon 22(1), 58-63.
  • Gursoy A, Gursoy N. 2015. On the Flexibility Constrained Line Balancing Problem in Lean Manufacturing. Tekstil ve Konfeksiyon 25(4), 345-351.
  • Xu H, Xu B, Yan J. 2019. Balancing Apparel Assembly Lines Through Adaptive Ant Colony Optimization. Textile Research Journal 89(18), 3677–3691.
  • Ahmed N, Ador MSH. 2020. Multi-Objective Mixed Model Assembly Line Balancing Using Mixed Integer Linear Programming. American Journal of Industrial Engineering 7(1), 14-25.
  • Helgeson WP, Birnie DP. 1961. Assembly Line Balancing Using the Ranked Positional Weight Technique. Journal of Industrial Engineering, 12(6), 384-398.
  • LINGO. 2015. The Modeling Language and Optimizer. Chicago, Illinois: LINDO Systems Inc.
There are 23 citations in total.

Details

Primary Language English
Subjects Wearable Materials
Journal Section Articles
Authors

Şeyda Topaloğlu Yıldız 0000-0001-6827-126X

Gülseren Karabay 0000-0002-1231-2816

Early Pub Date December 28, 2022
Publication Date December 31, 2022
Submission Date November 8, 2021
Acceptance Date September 28, 2022
Published in Issue Year 2022 Volume: 32 Issue: 4

Cite

APA Topaloğlu Yıldız, Ş., & Karabay, G. (2022). Balancing The Shirt Production Line Under Different Operational Constraints Using An Integer Programming Model. Textile and Apparel, 32(4), 353-365. https://doi.org/10.32710/tekstilvekonfeksiyon.1020866

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