Productivity Improvement of Assembly Line-by-Line Balancing Technique: Case Study Textile Manufacturing Company Karachi Pakistan

Abstract

The study on assembly line balancing theory and concept, focusing on the textile sector in Karachi, Pakistan, specifically the stitching department of a company, aimed to enhance efficiency through meticulous analysis and optimization. By employing time and motion analysis techniques, the research sought to identify and eliminate redundant activities, ensuring a seamless workflow with minimal idle time. The methodology employed involved a comprehensive observation of the entire production process, starting from stitching through to packing. This involved using a stopwatch to meticulously analyze each step of the process, thus gaining insight into the current operational dynamics of the assembly line. Line balancing was ensured by calculating Standard Allowed Minutes (SAM), assessing capacity, and determining the required manpower and machine resources. To further refine the efficiency of the stitching line, data collection was conducted using stopwatch techniques, to devise an improved layout. By reducing processing time and minimizing unproductive intervals, the study aimed to establish a foundation for enhanced productivity and streamlined work orders. Various tools were utilized to scrutinize the procedures involved in the production process, encompassing activities, operator proficiency, equipment efficiency, and material usage. This comprehensive approach aimed to optimize the workflow, making it more ergonomic and conducive to efficient operations while ensuring worker satisfaction. The study's analysis specifically targeted the stitching operations related to sheet sets, with a focus on minimizing the number of machines and achieving optimal line capacity. Significant reductions in machine requirements were achieved, with the number of machines for both sheet sets and fitted sheets being reduced substantially. Capacity calculations based on SAM and machine numbers demonstrated the achievement of production targets. Moreover, manpower requirements were reassessed and optimized, resulting in a reduction in the number of workers required for packing operations, thereby further enhancing efficiency.