An effective integer program for a general assembly line balancing problem with parallel workers and additional assignment restrictions

Pearce, Bryan; Antani, Kavit; Mears, Laine; Funk, Kilian; Mayorga, Marı́a E.; Kurz, Mary E.

doi:10.1016/j.jmsy.2018.12.011

Cited by 29 publications

(10 citation statements)

References 22 publications

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“…Therefore, applied line balancing problems which has been derived from GABLP are most suitable for such systems. 39 The applied line balancing problems in garment manufacturing evolved because garment assembly line poses unique balancing problems to those of large body assembly lines such as trucks, buses, aircraft, and machines. 40,41 In most studies, garment assembly line balancing has been implemented using several techniques including ranked positional weight, 42 COMSOAL, 43 largest candidate rule, 44 and simulation.…”

Section: Assembly Line Balancingmentioning

confidence: 99%

“…The NYTIL trouser assembly line right hip pocket (20)(21)(22)(23)(24), knee pocket preparation (KPP) for making both left and right knee pocket (32)(33)(34)(35)(36), knee flap preparation (KFP) for making both left and right knee flap (38)(39)(40)(41)(42), big loop preparation (BLP) for making seven big loops per trouser (47)(48)(49)(50)(51), small loop preparation (SLP) for stitching small loops and cutting into seven pieces required per trouser (52), adjustable rope preparation (ARP) for cutting and attaching two sets of adjustable rope at two positions on trouser waist band (65)(66), and main body assembly (MBA) for assembling all the prepared parts and other parts (do not require preparation) to the trouser body and involves other operations such as trimming, turning, quality checking, and…”

Section: F I G U R Ementioning

confidence: 99%

“…However, these borders are frequently transgressed in real‐life situations, in particular for complex assembly line systems like most garment manufacturing. Therefore, applied line balancing problems which has been derived from GABLP are most suitable for such systems 39 . The applied line balancing problems in garment manufacturing evolved because garment assembly line poses unique balancing problems to those of large body assembly lines such as trucks, buses, aircraft, and machines 40,41 …”

Section: Literature Reviewmentioning

confidence: 99%

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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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Section: Assembly Line Balancingmentioning

confidence: 99%

Section: F I G U R Ementioning

confidence: 99%

Section: Literature Reviewmentioning

confidence: 99%

See 1 more Smart Citation

A complex garment assembly line balancing using simulation‐based optimization

Bongomin

Mwasiagi

Nganyi

et al. 2020

Engineering Reports

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“…Many ALBP methods have been examined in the study of manufacturing systems, including the heuristic algorithm [16][17][18][19][20][21][22][23][24], artificial bee colony algorithm [25][26][27], genetic algorithm [28][29][30], branch-and-bound algorithm [31][32][33][34], imperialist competitive algorithm [35], Pareto Greedy algorithm [36], memetic ant algorithm [37], whale optimization algorithm [38], recursive algorithm [39], fuzzy linear programming [40], swarm algorithm [41,42], simulated annealing algorithm [43], and data envelopment analysis [44]. The genetic algorithm [45,46] and artificial bee colony algorithm [47] have been used to solve the ALBP in remanufacturing systems.…”

Section: Introductionmentioning

confidence: 99%

An Algorithm for Arranging Operators to Balance Assembly Lines and Reduce Operator Training Time

2021

Applied Sciences

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Industry 4.0 is transforming how costs, including labor costs, are managed in manufacturing and remanufacturing systems. Managers must balance assembly lines and reduce the training time of workstation operators to achieve sustainable operations. This study’s originality lies in its use of an algorithm to balance an assembly line by matching operators to workstations so that the line’s workstations achieve the same targeted output rates. First, the maximum output rate of the assembly line is found, and then the number of operators needed at each workstation is determined. Training time is reduced by matching operators’ training and skills to workstations’ skill requirements. The study obtains a robust, cluster algorithm based on the concept of group technology, then forms operator skill cells and determines operator families. Four numerical examples are presented to demonstrate the algorithm’s implementation. The proposed algorithm can solve the problem of arranging operators to balance assembly lines. Managers can also solve the problem of worker absences by assigning more than one operator with the required skillset to each workstation and rearranging them as needed.

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“…The balanced assembly line can not only improve the production efficiency, but also can ensure the effective timing of the machines [19,20] and reduce the carbon emission in the production process. The balance study of garment sewing assembly lines is mainly a single model [21,22]. Most research mainly focuses on the mechanical and electronic field, while little research focuses on the balance optimization of the sewing line [23].…”

Section: Introductionmentioning

confidence: 99%

Carbon Emission Evaluation Based on Multi-Objective Balance of Sewing Assembly Line in Apparel Industry

Zhang

Chen

2019

Energies

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Apparel manufacturing is an industry with high energy consumption and carbon emissions. With the development of the low-carbon economy, low-carbon production in the apparel manufacturing industry become more and more imperative. The apparel industry is encountering great challenges in reducing carbon emissions. Garment sewing comprises a large number of processes, machines and operators. However, the existing studies lack quantitative analysis of carbon sources in the sewing process. This study analyzed the carbon emission characteristics in garment sewing production. Evaluation models of carbon emission were established for the sewing process in this research and the factors of fabrics, accessories, sewing machines and operators were included in the models. The results showed that fabrics and accessories were the main sources of carbon emissions in garment sewing production. The second largest carbon emission source was sewing machines, followed by operators. According to the evaluation models, the number of machines, operators and the utilization rate of the machines were related to the balance of the assembly line. A multi-objective optimization model aimed at minimizing the time loss rate and smoothness index of the assembly line was established, and a fast and elitist multi-objective genetic algorithm was used to obtain the solution for carbon emission reduction. The men’s shirt assembly lines, based on three types of workstation layouts (the order of processes, the type of machines and the components of the garment), were applied to verify the effectiveness of the model and algorithm. The results indicated that the total carbon emissions of the three assembly lines based on balance optimization were less than that of the normal assembly line. The assembly line of the workstations arranged in the order of processes was the best assembly line since it had the highest efficiency and the lowest carbon emissions.

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An effective integer program for a general assembly line balancing problem with parallel workers and additional assignment restrictions

Cited by 29 publications

References 22 publications

A complex garment assembly line balancing using simulation‐based optimization

A complex garment assembly line balancing using simulation‐based optimization

An Algorithm for Arranging Operators to Balance Assembly Lines and Reduce Operator Training Time

Carbon Emission Evaluation Based on Multi-Objective Balance of Sewing Assembly Line in Apparel Industry

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