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Email address:
mazh999@gmail.com (Md. M. Islam), tanjimseu@yahoo.com (Md. T. Hossain), jalil.mbstu@gmail.com (M. A. Jalil),
eliaskhalil52@gmail.com (E. Khalil)
Abstract: In this modern world, fashion & styles are changing frequently. The emergence of fast changes in fashion has given
rise to shorten production cycle time in the garment industry. To meet the dynamic customer demands of momentous quantities in
shorten lead time, assembly line production systems are used, where the garment components are assembled into a finished
garment through a sub-assembly process. So in the era of product customization, the optimal usage of resources especially the
available facilities & operators who are adding the value of product is important. Therefore the assembly line has to be planned in
much more flexible way. This paper deals with the maximum utilization of manpower in labor intensive assembly lines. The
objective is to accurately delegate workers to the various operations required to complete the product based on their skill &
experience so as to achieve the highest level of productivity and delivery as per planned target. The experimental result showed
meaningful improvement in productivity as compared to the existing system.
1. Introduction
As a supply chain of textile industry, garment industry is
one of the major industries of the world. The production
process of garments is separated into four main phases:
designing/ clothing pattern generation, fabric spreading &
cutting, sewing and ironing & packing. The most critical
phase is sewing phase [1]. As the sewing is the heart of
apparel industry, we have to design the sewing line properly
so as to achieve the best output at maximum efficiency.
Apparel is a mass production system. Assembly line
production systems are developed to meet the requirements
of mankind, which continue to grow day by day [2]. The
demand for greater product variability and shorter life cycles
has caused traditional production methods to be replaced
with assembly lines [3]. Assembly line is an industrial
arrangement of machines, equipments and workers for
continuous flow of work pieces in mass production operation.
Manufacturing a product in an assembly line requires
partitioning the total amount of work into a set of elementary
2. Literature Review
A line is defined as a group of operators under the control of
one production supervisor [10]. Balancing is the technique of
maintaining the same level of inventory at each and every
102
4. Experimental Data
Operational Bulletin of Jacket before and after
arrangement, Breakdown of different machines before and
after rearrangement along with comparison of productions
are shown below in different tables.
Process Name
Name
M/c Type
Performed
SMV
Allocated
SMV
Output @
100% eff
Efficiency %
1
2
3
4
5
Jarna
Naher
Hasina
Eima
Mena
O/L
F/L
O/L
O/L
F/L
0.64
0.35
1.72
1.28
0.62
0.62
0.3
0.62
0.62
0.55
96.77
200.00
96.77
96.77
109.09
96
87
36
48
89
Output @
performed
efficiency %
93.26
173.08
34.95
46.88
97.30
SL
Process Name
Name
M/c Type
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Ronju
Monzilla
Amina
Sahina
Nurbanu
Lima
Alima
Rojina
Morina
Sokina
Momina
Pervin
Rebeka
Roksana
Sabina
Rojina
Bobita
Shahanara
Sabina
Shahila
Naher
Halima
Orchona
Beauty
Sharmin
O/L
L/S
O/L
O/L
F/L
O/L
F/L
O/L
O/L
F/L
F/L
L/S
L/S
O/L
L/S
L/S
L/S
L/S
L/S
L/S
L/S
L/S
L/S
L/S
O/L
Performed
SMV
Allocated
SMV
0.78
0.5
0.53
0.3
0.82
0.62
0.79
0.62
0.53
0.55
0.94
0.43
0.88
0.42
0.92
0.59
0.64
0.45
0.47
0.49
0.42
0.3
0.79
0.63
0.26
0.22
0.43
0.39
0.88
0.42
0.87
0.5
0.66
0.3
0.45
0.57
1.77
0.78
1.99
0.78
0.36
0.42
0.58
0.5
0.76
0.69
0.66
0.5
0.36
0.3
Max Theoretical output
103
Output @
100% eff
Efficiency %
120.00
200.00
96.77
96.77
109.09
139.53
142.86
101.69
133.33
122.45
200.00
95.24
272.73
153.85
142.86
120.00
200.00
105.26
76.92
76.92
142.86
120.00
86.96
120.00
200.00
76.92
64
57
76
78
103
46
48
64
70
104
71
80
85
90
48
57
45
127
44
39
118
86
90
76
83
practical output
Output @
performed
efficiency %
76.60
113.92
73.47
75.95
112.50
63.60
68.18
65.45
93.26
126.76
141.73
75.95
230.77
138.46
68.44
68.97
90.91
133.33
33.90
30.15
168.22
103.45
78.60
90.91
165.14
30 pcs
Process Name
Name
M/c Type
Performed SMV
Efficiency
Monzilla
L/S
0.53
57%
17
Collar make
Pervin
L/S
0.79
80%
18
Rebeka
L/S
0.26
85%
20
Sabina
L/S
0.88
48%
21
Rojina
L/S
0.87
57%
22
Bobita
L/S
0.66
45%
23
Shahanara
L/S
0.45
127%
24
Collar join
Sabina
L/S
1.77
44%
25
Collar join
Shahila
L/S
1.99
39%
26
Naher
L/S
0.36
118%
27
Halima
L/S
0.58
86%
28
Orchona
L/S
0.76
90%
29
Beauty
L/S
0.66
76%
Process Name
Collar twill tape attach
Zipper tuck with body
Zipper patch attach at bottom
Front part panel ts & tc
Zipper join with left side
Zipper holding tuck
Zipper facing join
Zipper join right side
Collar make
Zipper twill tape attach
Zipper twill tape make
Collar join
Collar join
Name
Shahila
Sabina
Bobita
Sabina
Monzilla
Rojina
Beauty
Pervin
Rebeka
Halima
Orchona
Naher
Shahanara
M/c Type
L/S
L/S
L/S
L/S
L/S
L/S
L/S
L/S
L/S
L/S
L/S
L/S
L/S
Performed SMV
0.26
0.36
0.45
0.53
0.58
0.66
0.66
0.76
0.79
0.87
0.88
1.77
1.99
Efficiency
39%
44%
45%
48%
57%
57%
76%
80%
85%
86%
90%
118%
127%
104
Process Name
Back part panel join
Left and right panel join
Left and right panel join
Front part panel join & tc
Left & right panel join
Left and right panel join
Shoulder panel join
Shoulder join
Sleeve panel make
Collar serving
Zipper facing o/l
Name
Jarna
Hasina
Eima
Ronju
Amina
Sahina
Lima
Rojina
Morina
Roksana
Sharmin
M/c Type
O/L
O/L
O/L
O/L
O/L
O/L
O/L
O/L
O/L
O/L
O/L
Performed SMV
0.64
1.72
1.28
0.78
0.82
0.79
0.94
0.92
0.64
0.43
0.36
Efficiency
96%
36%
48%
64%
76%
78%
46%
64%
70%
90%
83%
Process Name
Zipper facing o/l
Collar serving
Sleeve panel make
Back part panel join
Front part panel join & tc
Left and right panel join
Left & right panel join
Shoulder join
Shoulder panel join
Left and right panel join
Left and right panel join
Name
Hasina
Lima
Eima
Ronju
Rojina
Morina
Amina
Sahina
Sharmin
Roksana
Jarna
M/c Type
O/L
O/L
O/L
O/L
O/L
O/L
O/L
O/L
O/L
O/L
O/L
Performed SMV
0.36
0.43
0.64
0.64
0.78
0.79
0.82
0.92
0.94
1.28
1.72
Efficiency
36%
46%
48%
64%
64%
70%
76%
78%
83%
90%
96%
Process Name
Back panel ts tc
Left and right panel ts and tc
Left and right panel ts & tc
Shoulder panel ts
Sleeve panel top stitch & tc
Sleeve hem
Name
Naher
Mena
Nurbanu
Alima
Sokina
Momina
M/c Type
F/L
F/L
F/L
F/L
F/L
F/L
Performed SMV
0.35
0.62
0.53
0.88
0.47
0.42
Efficiency
87%
89%
103%
48%
104%
71%
Process Name
Back panel ts tc
Sleeve hem
Sleeve panel top stitch & tc
Left and right panel ts & tc
Left and right panel ts and tc
Shoulder panel ts
Name
Alima
Momina
Naher
Mena
Nurbanu
Sokina
m/c
F/L
F/L
F/L
F/L
F/L
F/L
Performed SMV
0.35
0.42
0.47
0.53
0.62
0.88
Efficiency
48%
71%
87%
89%
103%
104%
Process Name
Back part panel join
Back panel ts tc
Left and right panel join
Left and right panel join
Left and right panel ts and tc
Front part panel join & tc
Front part panel ts & tc
Left & right panel join
Left and right panel join
Left and right panel ts & tc
Shoulder panel join
Name
Ronju
Alima
Jarna
Roksana
Nurbanu
Rojina
Sabina
Amina
Morina
Mena
Sharmin
M/c Type
O/L
F/L
O/L
O/L
F/L
O/L
L/S
O/L
O/L
F/L
O/L
Performed SMV
0.64
0.35
1.72
1.28
0.62
0.78
0.53
0.82
0.79
0.53
0.94
Efficiency %
48
48
96
90
71
64
44
76
70
87
83
SN
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Process Name
Shoulder panel ts
Shoulder join
Sleeve panel make
Sleeve panel top stitch & tc
Sleeve hem
Collar make
Collar twill tape attach
Collar serving
Zipper twill tape make
Zipper twill tape attach
Zipper holding tuck
Zipper patch attach at bottom
Collar join
Collar join
Zipper tuck with body
Zipper join with left side
Zipper join right side
Zipper facing join
Zipper facing o/l
Name
Sokina
Sahina
Eima
Naher
Momina
Rebeka
Shahila
Lima
Orchona
Halima
Rojina
Bobita
Naher
Shahanara
Sabina
Monzilla
Pervin
Beauty
Hasina
M/c Type
F/L
O/L
O/L
F/L
F/L
L/S
L/S
O/L
L/S
L/S
L/S
L/S
L/S
L/S
L/S
L/S
L/S
L/S
O/L
Performed SMV
0.88
0.92
0.64
0.47
0.42
0.79
0.26
0.43
0.88
0.87
0.66
0.45
1.77
1.99
0.36
0.58
0.76
0.66
0.36
Efficiency %
89
78
64
103
104
86
39
46
48
57
45
85
118
127
57
76
90
80
36
105
Process Name
Back part panel join
Back part panel join
Back panel ts tc
Left and right panel join
Left and right panel join
Left and right panel ts and tc
Front part panel join & tc
Front part panel ts & tc
Left & right panel join
Left and right panel join
Left and right panel ts & tc
Shoulder panel join
Shoulder panel ts
Shoulder join
Sleeve panel make
Sleeve panel top stitch & tc
Sleeve hem
Collar make
Collar twill tape attach
Collar serving
Zipper twill tape make
Zipper twill tape attach
Zipper holding tuck
Zipper patch attach at bottom
Collar join
Collar join
Zipper tuck with body
Zipper join with left side
Zipper join right side
Zipper facing join
Zipper facing o/l
Name
Raju
Ronju
Alima
Jarna
Roksana
Nurbanu
Rojina
Sabina
Amina
Morina
Mena
Sharmin
Sokina
Sahina
Eima
Naher
Momina
Rebeka
Shahila
Lima
Orchona
Halima
Rojina
Bobita
Naher
Shahanara
Sabina
Monzilla
Pervin
Beauty
Hasina
M/c Type
O/L
O/L
F/L
O/L
O/L
F/L
O/L
L/S
O/L
O/L
F/L
O/L
F/L
O/L
O/L
F/L
F/L
L/S
L/S
O/L
L/S
L/S
L/S
L/S
L/S
L/S
L/S
L/S
L/S
L/S
O/L
Performed SMV
0.64
0.64
0.35
1.72
1.28
0.62
0.78
0.53
0.82
0.79
0.53
0.94
0.88
0.92
0.64
0.47
0.42
0.79
0.26
0.43
0.88
0.87
0.66
0.45
1.77
1.99
0.36
0.58
0.76
0.66
0.36
Efficiency %
48
48
48
96
90
71
64
44
76
70
87
83
89
78
64
103
104
86
39
46
48
57
45
85
118
127
57
76
90
80
36
Before Rearrangement
30
30
30
After Rearrangement
30
30
46
106
6. Conclusion
[6]
[7]
[8]
[9]
Skill matrix helps in allocating right person for the right job
which helps in achieving desired performance level. It keeps
record of all operations an operator had done in the past and
efficiency level in each operation. Engineers / line supervisors
need minimum time to find and select most efficient operators
for an operation from the pull of operators. For line balancing,
operators can be selected according to work content. When
someone is absent, supervisor can easily find suitable person
from the skill matrix table and replace. To analyses the skill
availability and distribution throughout the factory. This can
be compared with the skill requirement for a particular time
period and shortage/excess skill availability to achieve at the
training requirement. So productivity can be achieved by
allocating skill & semi-skilled workers to the right place and
unskilled operator should be trained properly.
References
[1]
Chen J.C., Chen C.C., Lin Y.J., Lin C.J., and Chen T.Y.
Assembly Line Balancing Problem of Sewing Lines in
Garment Industry. International Conference on Industrial
Engineering and Operations Management, Bali, Indonesia,
2014.
[2]
[3]
[4]
[5]