Productivity Improvement of BOB T-shirt through Line Balancing Using Control Limit analysis and discrete event simulation (Case study: - MAA Garment and Textile Factory)

Abstract

This study deals with line balancing of BOB T-shirt model with the help of control limit analysis and discrete event simulation of the assembly lines. In this study control limit analysis is used to measure the performance of the assembly line and used to show the bottleneck operations of the assembly line and line balancing technique improves the productivity of the sewing line of the model. BOB T-shirt model has 16 main operations and each operation’s time is analyzed as standard minute value (SMV). The main bottleneck operations are analyzed using the control limit analysis and simulation modeling. Based on the SMV of each operation, those operations which are out of lower control limit and upper control limit is called us bottlenecks of the sewing lines of the garment section and the 1st bottleneck operation is tread trimming operation. When we apply control limit analysis and discrete event simulation technique for the line balancing; the daily output has been increased from 1032 pieces to 1289 pieces. And labor productivity and machine productivity are increased from 46.9 and 54.32 to 58.59 and 71.61 respectively. And then finally, the profit that the line generated also increased from 22704 to 28358birr.