Abstract
One of the most used production systems is the assembly line balancing which is used to improve or balance different production line of different industries all over the world. This paper is about improving the productivity of a particular sewing line of a Duffle Trolley (DFT) bag of VIP Industries Bangladesh Private Limited by balancing the line. By balancing the line product can be produced at a high production rate in the shortest time with an optimum productive way which is also cheap and demanded quality. This paper identifies the opportunities for improvement of current sewing line by performing RPWM (Ranked Positional Weight Method) line balancing technique and testing feasibility using Tecnomatix simulation software. In this study, at first-time study of each operation was performed. For each process SMV (standard minute value), the existing line efficiency and production cycle time also labor productivity were calculated. Then using the precedence diagram and RPWM a balanced line layout was found and the line was tested by Tecnomatix software for validity. The final result obtained was an optimized and improved balance line layout for the sewing line. Finally, following this, the company will be able to produce the product at a high production rate through the minimum cost and meet the daily production target.
Highlights
Line balancing means the work element to be allocated in many work stations to balance a line for better productivity
This paper identifies the opportunities for improvement of current sewing line by performing RPWM (Ranked Positional Weight Method) line balancing technique and testing feasibility using Tecnomatix simulation software
This paper focuses on single model line balancing problem with real application in garment manufacturing industry
Summary
Line balancing means the work element to be allocated in many work stations to balance a line for better productivity. Unequal workload in workstations of a sewing line or production line in an industry will increase Work-in-Process and waiting time. Both production cycle time and cost are increased. Line balancing presents a significant way to reduce workers, idle time, reduce work in process, increase productivity etc. Main purposes of this study are to perform work study on the manual operators’ activities, to establish standard time for manual process, to determine the current operator’s utilization, to make recommendations to achieve efficient manpower planning, to test the feasibility of layout by computer simulation and to improve productivity and efficiency of existing layout by implementing new layout
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