A complex garment assembly line balancing using simulation‐based optimization

Bongomin, Ocident; Mwasiagi, Josphat Igadwa; Nganyi, Eric Oyondi; Nibikora, Ildephonse

doi:10.1002/eng2.12258

Cited by 13 publications

(8 citation statements)

References 68 publications

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“…This is because it reduces both cycle time and WIP. In spite of the fact that the metamodel was not used for model prediction, the present study found it most suitable for inference [30], and for initial solution (local optimal) for optimization process [52]. The inference was drawn from the linear regression metamodel to analyze the factors' effects on throughput.…”

Section: Plos Onementioning

confidence: 90%

Simulation metamodeling approach to complex design of garment assembly lines

et al. 2020

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The today's competitive advantage of ready-made garment industry depends on the ability to improve the efficiency and effectiveness of resource utilization. Ready-made garment industry has long historically adopted fewer technological and process advancement as compared to automotive, electronics and semiconductor industries. Simulation modeling of garment assembly line has attracted a number of researchers as one way for insightful analysis of the system behaviour and improving its performance. However, most of simulation studies have considered ill-defined experimental design which cannot fully explore the assembly line design alternatives and does not uncover the interaction effects of the input variables. Simulation metamodeling is an approach to assembly line design which has recently been of interest to researchers. However, its application in garment assembly line design has never been well explored. In this paper, simulation metamodeling of trouser assembly line with 72 operations was demonstrated. The linear regression metamodel technique with resolution-V design was used. The effects of five factors: bundle size, job release policy, task assignment pattern, machine number and helper number on throughput of the trouser assembly line were studied. An increase of the production throughput by 28.63% was achieved for the best factors' setting of the metamodel.

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Section: Plos Onementioning

confidence: 90%

Simulation metamodeling approach to complex design of garment assembly lines

et al. 2020

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“…Therefore, simulation-based optimization techniques are widely used to evaluate the optimization problems of complex manufacturing systems. Bongomin et al [31] applied Arena software to develop the discrete event simulation of the assembly line, and both local and global optimization methods have significantly improved the production efficiency of the assembly line.…”

Section: Related Studiesmentioning

confidence: 99%

Digital Twins-Based Production Line Design and Simulation Optimization of Large-Scale Mobile Phone Assembly Workshop

Zhao

Zou

et al. 2022

Machines

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The mobile phone is a typical 3C electronic product characterized by frequent replacement, multiple product specifications, high flexibility, high-frequency production line switching, and urgent delivery time during production. Therefore, the optimized design of the mobile phone production workshop is crucial. This paper takes the assembly process of a specific type of mobile phone assembly as the research object and adopts the heuristic balance method to combine the production procedures. Moreover, it considers the automation degree of the process and the demand for production line rhythm to carry out station division and working hours design for the assembly process. The advantages and disadvantages of the plug-and-play production line and unit production line architecture are integrated, aiming at the production line’s construction cost and unit area capacity. A hybrid workshop with a mixed combination of two types of production lines is designed and an optimization model of hybrid workshop design is established. The semi-physical simulation technology of digital twins is utilized to verify the proposed design scheme to achieve the balance optimization of the production line, improve production efficiency, and reduce production costs. This work provides a technical scheme for designing and optimizing large-scale mobile phone assembly workshops with multi-batch and high-frequency production changes.

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“…Moreover, the optimization approaches can be integrated to simulation techniques which is called simulation-based optimization approaches. These approaches have been adopted to manufacturing systems' optimization, efficiently [46]. For example, [47] developed a simulation-based optimization approach using a discrete event simulation model and simulated annealing (SA) algorithm, to solve a production planning and resource allocation problem in reconfigurable manufacturing system.…”

Section: Optimization Approaches For Assembly Line Balancingmentioning

confidence: 99%

A skill- and feature-based approach to planning process monitoring in assembly planning

Gonnermann

Hashemi-Petroodi

Thevenin

et al. 2022

Int J Adv Manuf Technol

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Frequent changes in customer needs and large product variety are forcing manufacturing companies to move from mass production to mass customization. Customized production can be achieved by introducing reconfigurable production systems (RMS). The customized flexibility and several characteristics of RMSs provide many opportunities in terms of process and production planning. However, those characteristics greatly increase the complexity of the design and planning of production systems. This paper presents a decision support system relying on a skill-based approach to design a reconfigurable assembly line considering the planning of assembly processes and monitoring. The proposed decision aid system is modular in design and is composed of four modules. The main input data is a CAD model of a new product variant for the identification of the assembly and monitoring requirements. Besides, a current assembly system layout with its resource descriptions exists. In the first developed module, assembly-by-disassembly and a skill-based approach are used to generate different assembly plans. In the second module, feature recognition and skill-based approaches generate process monitoring alternatives. The third module uses a linear program (LP) that aims to minimize the total cost of workstation activation and reconfiguration, as well as cycle time, and to maximize the process quality of the assembly tasks. A user-based generative model design approach is applied to optimize the values of three objective functions. In the fourth and final module, a simulation of the optimized assembly plan allows either the validation of the assembly plan and process monitoring plan or initiates a new iteration due to their infeasibility. To further demonstrate how the proposed methodology works, some computational experiments are provided for two use cases.

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A complex garment assembly line balancing using simulation‐based optimization

Cited by 13 publications

References 68 publications

Simulation metamodeling approach to complex design of garment assembly lines

Simulation metamodeling approach to complex design of garment assembly lines

Digital Twins-Based Production Line Design and Simulation Optimization of Large-Scale Mobile Phone Assembly Workshop

A skill- and feature-based approach to planning process monitoring in assembly planning

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