Journal of Textile Engineering & Fashion Technology

Review Article Open Access

Bi-dimensional simulation tool of elementary

motions on a sewing workstation
Abstract Volume 3 Issue 5 - 2017

In these times of rising costs, increasing competition, and falling sales prices in the
Nahed Jaffel Memmi, Najeh Maâtoug, Faouzi
garment industry, it is of particular importance that productivity is maximized. This
research is focused on the design and development of a tool that can simulate elementary
Sakli
Textile engineering laboratory, University of Monastir, Tunisia,
gestures and movements on a sewing workstation and calculate the expected time of
each operation using the GSD method which is the adequate predetermined motion Correspondence: Nahed Jaffel Memmi, Textile engineering
time system for the sewn products and apparel industries. The digital simulation of laboratory, University of Monastir, Hadj Ali Soua Avenue, PO
gestures and postures of the operator was possible by using bi-dimensional human Box 68, Ksar Hellal 5070, Tunisia, Tel 216 2606 9428,
digital model, but it is still relatively complex due to the variety and complexity of the Email [email protected]
human behavioral states.
Received: December 07, 2017 | Published: December 20,
Keywords: time, 2d simulation, gesture, sewing workstation 2017

Abbreviations: GSD, general sewing data; DHM, digital hu- a. Improving operation time measurement.
mans model; O&M, organization & methods; GSD, general sewing b. Producing a precise analysis of each operation including its ele-
data mentary gestures.
Introduction The outcome of the study was the definition of the functional
specifications of a computer program designed to calculate the
In a competitive industrial environment, time has become the key
execution time of each operation, simulate and visualize its different
factor to success as it is a strategic variable in business management.
steps respecting the chronological order predefined by the user.
Predetermined motion time system, particularly General Sewing Data
(GSD) method allows us to analyze and plan every single operation in Design and development of the Program
the sewing of a garment, whether it’s a machine or a manual operation.
Primary design
Developing adequate tools for time measurement in the industrial
environment has become important especially in the textile industry The primary design includes choosing the program’s architecture
as operating times vary tremendously depending on technological and and its division into modules. In this step we translate the user
human factors which are rather difficult to predict. requirements into a computer based solution. To do so, we followed
the waterfall development model.2
However, it’s possible to create time measurement tools as well
as various simulation programs, such as the digital humans model According to the functional specifications, a web application is
(DHM), which were designed to simulate and reproduce human the best technology for our study case and the adopted architecture is
behavior and gestures. client-server architecture. A computer program following the client-
server architecture can be divided into three layers: the data layer, the
The goal of this work is to develop a computer tool dedicated to
data processing layer and the data presentation layer. According to
solve the time measurement problematic for human-operated textile
this model, our program has three main modules (Figure 1): One for
workstations while taking into account the various constraints that
human-machine interfaces that handles data display and interaction
directly affect the operations execution time. This program will also
with the user, another for Inputs and transformation that makes data
simulate the operation’s course (succession of the elementary gestures
usable by the application-level processing mechanisms and a third for
involved).
the actual data processing that performs the actions requested by the
In this paper we describe the process of designing this tool and user such as calculations and simulations.
the different steps preceding its programming. We start up with a
feasibility study which is a crucial step in a project of this extent. Detailed design
The feasibility study includes an assessment of the current operations’ In the detailed design phase we define the different interfaces and
mode and existing processes and a precise description of the human, diagrams and we choose the programming languages to implement.
material and organizational factors surrounding the pilot workstation. The diagram of the main menu interface includes the following
This analysis enabled us to determine the problems of the factory’s sections: Home, About, GSD Card, Operations elements and stitching
Organization & Methods (O&M) department identify its needs and parameters and recorded operations.
create the appropriate solutions. The main problems that we could
identify were: the lack of a precise operation’s time measurement and For programming the tool, we used XAMPP which is a cross-
prediction tool and the absence of a complete and accurate gesture platform server package that contains APACHE web server, a PHP
analysis technique. Therefore, to resolve these problems, we set the engine and a MySQL database server. This Web development platform
following goals according to the SMART Model:1 allows our program’s PHP scripts to run locally without connecting to
an external server.

Submit Manuscript | http://medcraveonline.com J Textile Eng Fashion Technol. 2017;3(5):713‒716. 713

© 2017 Memmi et al. This is an open access article distributed under the terms of the Creative Commons Attribution License, which
permits unrestricted use, distribution, and build upon your work non-commercially.
 Copyright:
Bi-dimensional simulation tool of elementary motions on a sewing workstation ©2017 Memmi et al. 714

Figure 1 Different layers of a web application.

Programming operation’s sam computation

SAM or Standard Allowed Minute is used to measure task or work
content of a garment. For the estimation of cost of making a garment
SAM value plays a very important role. According to the research
study minute value has been defined for each movement needed to
accomplish a job. Synthetic data is available for each movement.
General Sewing Data (GSD) has defined set of codes for motion data
for SAM calculation. General Sewing Data provides the ability to Figure 2 Body segments and joints of the human body.
establish and quantify each step or operation in the manufacturing
process. This method allows us to analyze and plan every single Bust: consists of three segmental regions corresponding to three
operation in the sewing of a garment, whether it’s a machine or a groups of vertebrae: lumbar spine, thoracic spine and cervical spine.
manual operation. In our study we used the GSD codes to establish We focus on the movements of the torso as a whole. As a unit the
Standard Time of a garment. bust can perform three types of movements: flexion-extension, tilt or
lateral bending, and axial rotation movements. The bust is modeled by
At first we defined the operation to study: the assembling operation. three flexibility degrees.5
Then we define all motions of that operation in one complete cycle of
work. The next step was to refer GSD synthetic data for TMU (Time Hands: The hand articulations are: shoulders, elbows and wrists.
measuring unit) values. To obtain the Basic Time in minutes we had to To simplify the model, we neglected the intermediate articulations
convert TMU value for the assembling operation into minutes. The we because we consider the hand as a single block. Accordingly, only the
calculate Standard allowed minutes as mentioned below: clavicle shoulder will be analyzed. The articular shoulder complex
is composed of three bones (scapula, clavicle and humerus) and five
(SAM) = (Basic minute + Bundle allowances + machine and joints Rockwood et al.6 We will consider the clavicle bone group to
personal allowances) (1) highlight the link between the bust and shoulders. Thus, the clavicle
Wit: Bundle allowances (10%), Machine and personal allowances is modeled by two flexibility degrees that generates two types of
(20%) Sabya et al.3 movements: the lifting and lowering movements, the anteposition-
retroposition movements.
Digital modeling of the human-environmrnt
Creating the digital model in an industrial environ-
system ment
Context The research starts with handmade sketches picturing an operator,
In our case, digital modeling involves the generation of a digital sitting behind a sewing machine (Figure 3). Once our handmade bi-
human model in a work environment to simulate the state of a seated dimensional model was segmented and its appearance defined, we
worker assembling a garment in a sewing workstation. We used a bi- created a bi-dimensional digital model representing the worker, the
dimensional model to represent this operator. In our study, we chose fabric and the machine. For the general simulation of the bi-dimension
to represent only five basic gestures of the GSD method and their digital human model in an industrial environment we followed the
different combinations that constitute the operation of assembling two approach inspired by literature explained in the following chart
fabrics, to finally choose the optimal solution. Chitescu (Figure 4):7

Anatomical and physiological articular analysis of the A. We started the modeling process with a digital representation of
the operator and the industrial environment separately (Figure
human body 5). The bi-dimensional digital model consists of three segments;
Since the operations are repetitive they can be represented by a the first and the second segments are successively the right and
sequence of points to reach. The target is to generate an automatic the left hands, and the last segment is the entire torso and head.
movement between different crossing points. The input data of each B. Thereafter, once the two models were validated, we achieved the
task are the initial posture of the model and the sequence of points digital modeling of the Human-Environment system. Based on
to reach. Our human model is constituted of two blocks (Figure 2):4

Citation: Memmi NJ, Maâtoug N, Sakli F. Bi-dimensional simulation tool of elementary motions on a sewing workstation. J Textile Eng Fashion Technol.
2017;3(5):713‒716. DOI: 10.15406/jteft.2017.03.00111
 Copyright:
Bi-dimensional simulation tool of elementary motions on a sewing workstation ©2017 Memmi et al. 715

this model and the last input of the movement simulation para-
meters, we performed a series of digital simulation for the ba-
sic gestural movements of the GSD method for each of the five
movements that constitute the assembling operation which are:
take pieces, bring parts under the presser foot, align or adjust
the two pieces, sewing operation and evacuating the assembled
piece with one hand.
C. This step was followed by a performance assessment for each
elementary movement. Once the performance validated, we
have conducted the digital simulation of the gestural activities
for different combinations of the elementary movements after
which we made an overall performance evaluation, to finally
choose the optimal solution (Figure 6). Figure 5 Digital sketch of the operator and the sewing workstation
designed with the simulation software

Figure 6 Screenshots of the animated gestural sequence modeling.

Conclusion
The result of this study is a web application with a user-friendly
Figure 3 Manual sketch of the sewing workstation and the digital human interface that allows us to calculate each operation’s time, including
model.
the technologic and the human times. The tool allows us to visualize
this operation in a 2D simulation. This work does not provide a
complete solution to the problems and difficulties encountered, but
we tried to develop a pilot application that will be subject to further
improvements and studies.
The web application developed in this study allows the
simulation of the five basic movements of stitching and their various
combinations that constitute the assembling operation and the choice
of the optimal solution. To achieve better results, the digital model
should be perfected to reach a higher level of accuracy by reproducing
all possible movements on a sewing workstation, a more realistic
definition of gestures’ pace and a realistic representation of fabric’s
behavior.

Acknowledgements
None.

Conflict of interest
Author declares there is no conflict of interest in publishing the
article.

References
Figure 4 General approach for the digital human model design in its 1. Mannion M, Keepence B. Smart Requirements. ACM SIGSOFT Softwa-
environment. re Engineering Notes. 1995;20(2):42‒47.

Citation: Memmi NJ, Maâtoug N, Sakli F. Bi-dimensional simulation tool of elementary motions on a sewing workstation. J Textile Eng Fashion Technol.
2017;3(5):713‒716. DOI: 10.15406/jteft.2017.03.00111
 Copyright:
Bi-dimensional simulation tool of elementary motions on a sewing workstation ©2017 Memmi et al. 716

2. Munassar NMA Govardhan A. A Comparison between Five Models 5. Vachon-Gee A. Exploratory study of the control of unic. Gradual isomet-
Of Software Engineering. International J Computer Science Issues. ric forces, Canada; 2012.
2010;7(5):1694‒0814.
6. Rockwood CA, Matsen FA, Wirth MA, et al. The Shoulder. Philadel-
3. Sabya SR, Subodh KG, Ripon C. Application of Industrial Engineering phia: Saunders Elsevier; 2009. p. 1704.
in Garments Sewing Floor, Daffodil International University, Bangla-
desh; 2012. p. 1‒80. 7. Chitescu LC. Simulation en ergonomie. Innovation factors in product
design, Lorrain. 2005;1:174‒193.
4. Manolova A, Debraux P. Description anatomique du movement. 2012.

Citation: Memmi NJ, Maâtoug N, Sakli F. Bi-dimensional simulation tool of elementary motions on a sewing workstation. J Textile Eng Fashion Technol.
2017;3(5):713‒716. DOI: 10.15406/jteft.2017.03.00111