Designing an Efficient Production System: A Case Study of a Clothing Company

Ciarapica, Filippo Emanuele; Crósta, Álvaro Penteado; Mazzuto, Giovanni; Paciarotti, Claudia

doi:10.5772/56842

Cited by 9 publications

(10 citation statements)

References 21 publications

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“…If the two sets of data compare "closely," the system's model is regarded as "valid.". A “valid” model can be used to make decisions similar to those that would be made if it were feasible and cost-effective to experiment with the system (Bevilacqua et al, 2013). Numerical statistics such as the sample mean, sample variance, and sample correlation function could be used to compare the model and system output data.…”

Section: Methodsmentioning

confidence: 99%

Designing Simulation to Improve Production Efficiency of Batik Industry

Kristiana,

Asih,

Sudiarso

2023

Simulation & Gaming

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Background The study deals with evaluating the production system for manufacturing batik, then developing a scenario for improving the system. Purpose The study aims to point out the possibilities of computerized simulations in designing, testing, and exploring scenario models of real production plants of Small-Medium enterprises (SMEs). Method The research is carried out as a case study, using a simulation approach to achieve the objectives. This study uses three data collection techniques: direct observation, qualitative interviews, and time study. The simulated model of the system is the basis for building improvement strategies. Results The simulation model yields more than 70% of the overall process time mainly consisting of idle time and waiting for the operator. It leads to an inefficient production system. Significant differences in processing time and assigning operators to workstations that are unbalanced cause inefficiency. Although most of the time was not efficient, the average utilization of the operator was 63.96%. The system has a good operator’s utility level because the average total utility value is higher than idle time. The operators are also responsible for other tasks that were included in the simulation. Discussion The study proves that simulation is a very promising approach that allows industrial owners to mimic the production process and resource assignments within the model. The production efficiency with existing resources can be enhanced with the balancing procedure between the workstations and the operators. The suggested system runs on the concept of assigning operators with lower utility to processes with high WIP queues. The operator can interact with multiple workstations. The proposed model reduces the total time required to produce the batik. Contribution The simulation helps the analyzed organization to evaluate the efficiency of the manufacturing process. Changing the parameters in the model can generate new utilization and efficiency for the system.

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Section: Methodsmentioning

confidence: 99%

Designing Simulation to Improve Production Efficiency of Batik Industry

Kristiana,

Asih,

Sudiarso

2023

Simulation & Gaming

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“…A model was tested by using a discrete-event simulation model in a clothing company and the study aims at improving the manufacturing process. Results indicate that the independent factors affect the production size in different dimensions (Bevilacqua et al, 2013). Besides that, another study aimed to reduce cycle time for several workstations by prioritizing the constraints of resources, resource types, and precedence relations.…”

Section: Literature Surveymentioning

confidence: 99%

Bi̇r Teksti̇l Şi̇rketi̇ İçi̇n Üreti̇m Hatti Atama Problemi̇

ABDELSALAM>¹,

MOHAMMOUD>²,

EDER>³

et al. 2023

Mühendislik Bilimleri Ve Tasarım Dergisi

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In this study, the production process of Karaman Textiles, for which production planning is done manually, was observed and analyzed. This study aims to minimize the unused machine capacity and idle time of the existing system by developing a mixed integer programming (MIP) model, developing scenarios, and obtaining the results with GAMS software. In addition, the results of the scenarios are compared and evaluated to reach the optimal result that meets and maximizes the efficiency of the production process. The company's usual production planning is done manually and determined according to annual demand. The study aims to minimize the machine working times and that complete planning of the production in the most optimal way. In this study, the company's production time and machine usage times were optimized, and under normal conditions, 15,000 fabric pants were produced for 8 hours a day, 5 days a week, and 4 weeks a month. The scenario analysis aimed to produce by adding 4,000 pieces of velvet pants in addition to 15,000 fabric pants in the first scenario. The second scenario aims to minimize the production time of 15,000 fabric pants by limiting the working times of the machines owned by the company.

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“…Recently, however, the interest in CPS-linked simulation has increased [15][16][17]. In the garment industry, simulation is used for various purposes such as the analysis of sewing waiting time, production capacity, and line balancing considering the state of the line [18][19][20]. Furthermore, optimization has been attempted to improve productivity at manufacturing sites by using methods such as big data analysis, GAs, and particle swarm methods [21][22][23].…”

Section: Literature Reviewmentioning

confidence: 99%

Simulation-Based Hybrid Optimization Method for the Digital Twin of Garment Production Lines

Jung

Park²,

Lee³

et al. 2021

Journal of Computing and Information Science in Engineering

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Implementing digital transformation in the garment industry is very difficult, owing to its labor-intensive structural characteristics. Further, the productivity of a garment production system is considerably influenced by a combination of processes and operators. This study proposes a simulation-based hybrid optimization method to maximize the productivity of a garment production line. The simulation reflects the actual site characteristics, i.e., process and operator level indices, and the optimization process reflects constraints based on expert knowledge. The optimization process derives an optimal operator sequence through a genetic algorithm, and sequentially removes bottlenecks through workload analysis based on the results. The proposed simulation optimization method improved productivity by ∼67.4%, which is 52.3% higher than that obtained by the existing meta-heuristic algorithm. The correlation between workload and production was verified by analyzing the workload change trends. This study holds significance because it presents a new simulation-based optimization model that further applies the workload distribution method by eliminating bottlenecks and digitizing garment production lines.

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Designing an Efficient Production System: A Case Study of a Clothing Company

Cited by 9 publications

References 21 publications

Designing Simulation to Improve Production Efficiency of Batik Industry

Designing Simulation to Improve Production Efficiency of Batik Industry

Bi̇r Teksti̇l Şi̇rketi̇ İçi̇n Üreti̇m Hatti Atama Problemi̇

Simulation-Based Hybrid Optimization Method for the Digital Twin of Garment Production Lines

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