Optimizing the Material-Product Transformation Processes in the Clothing Manufacturing Line

Abstract

In current economic conditions, one of the major problems in the textile and apparel industry is unable to determine the unnecessary movements of resources (operators, machines, materials). Especially during the production processes, to adjust and decrease the movements of the resources are more difficult, because the focus is mostly on the workers and materials. “Method Study” has developed for resolving these challenges. The string diagram which is one of the techniques of the method study, helps to provide minimum movements of the resources during manufacturing activities. In this study, the production activities of a clothing company were examined with the help of the string diagram to achieve the objectives of eliminating unnecessary movements of the resources, increasing the working speed, providing better working conditions, balancing the production lines. So in the study, the current status of the production system and the parts to be improved were determined. In this direction, the string diagram and line balancing methods were applied for improvements and generation of a new layout plan. As a result of the research, the journal distance of the pieces before sewing together for obtaining the end product was shortened by 39% and the number of operators working in the line was reduced from 32 to 26.