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PRODUCTIVITY IMPROVEMENT OF A GARMENT ASSEMBLY LINE USING

SIMULATION AND MODEL DRIVEN DECISION SUPPORT SYSTEM

Article  in  Journal of Engineering and Applied Sciences · February 2022

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 VOL. 17, NO. 4, FEBRUARY 2022 ISSN 1819-6608
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PRODUCTIVITY IMPROVEMENT OF A GARMENT ASSEMBLY

LINE USING SIMULATION AND MODEL DRIVEN DECISION
SUPPORT SYSTEM
Venkata Mallikharjuna Kishan Ivatury1 and Ketema Bobe Bonsa2
1
Department of Industrial Engineering, School of Mechanical and Industrial Engineering, Institute of Technology Hachalu Hundessa
Campus, Ambo University, Ambo, Ethiopia
2
Department of Mechanical Engineering, School of Mechanical and Industrial Engineering, Institute of Technology Hachalu Hundessa
Campus, Ambo University, Ambo, Ethiopia
E-Mail: [email protected]

ABSTRACT
The disruption caused due to the current pandemic situation in the areas of supply chains, tourism, aviation,
hospitality, sports and fashion is enormous. This effect is more visible in manufacturing sector especially in fashion, appeal
and garment industry. This resulted in the companies emphasizing on the effective utilization of resources and enhanced
productivity. Although, the concept of lean manufacturing, value stream mapping (VSM), Jidoka, Kaizen, 5S, Kanban,
Poka Yoke, line balancing and many more are available in the literature, that can enhance productivity, the incorporation of
data analytics and software-based simulations as a method to support decision making in real time production activity to
enhance productivity is the need of the hour. The aim of the research paper is to develop a framework of model driven
decision support system (MD-DSS) where real time data is fed to the system and data simulation and communication
technologies help in improving the productivity of the manufacturing process. An empirical study was conducted at AL
Apparel Manufacturing PLC, Addis Ababa (Ethiopia) garment manufacturing facility to demonstrate the proposed model.
Data is collected through observations, document studies, and time study measurements for skimmer trouser having 34
operations. The assembly line is balanced using discrete event Arena simulation program. The results indicated that the
proposed model has high line efficiency and increased productivity.

Keywords: assembly line, decision support system, arena.

1. INTRODUCTION that they produce [7]. They are divided into groups
Garments are an essential part of human beings’ according to the way they are produced. Assembly line
sustenance and existence. Garment industry has balancing methods are separated into three groups
traditionally been the first step towards industrialization in according to the solution approach: single model, multi-
any developing countries. The garment industry has model and mixed-model assembly lines [2]. Assembly line
experienced a massive growth in last four decades and balancing method-based solution approaches are threefold:
continues to be the strongest manufacturing sub-sector in Heuristic methods, analytical methods and simulation
developing countries. The textile and garments industry is techniques [8]. One of the most significant factors
one of the largest in the world and have a major role in the affecting the competitiveness of the garment industry
economy of any country [1, 2]. In garment industries which uses assembly lines is low productivity. The term
production systems are classified into mass production “productivity” can be used to assess or measure the extent
system and batch production system. In mass production to which a certain output can be extracted from a given
system, manufacturing facility is geared up to produce the input [9, 10].
products of interest in large volume, whereas in batch For this reason, assembly line balancing becomes
production system, manufacturing facility is geared up to very crucial for proper functioning of the assembly line
produce the products in much smaller volumes. A flow system. The balancing of assembly lines is an important
line may be used for the mass production system, which issue in manufacturing engineering, management, and
produces the same product over a long period of time. The control. Time standards are needed to manage a firm’s
batch production is realized through job shop production and operation effectively. Short- and long-term
implementation [3]. production planning of production, cost control and optical
An assembly line consists of a set of workstations utilization of resources and many more depend on
where a set of operations are carried out with the aim of establishing time standards for the operations [11].
obtaining the final product [4]. In assembly line, tasks are The operation, production, control and plans
allocated to the workstations considering some restrictions which are performed according to the standard time
including precedence constraints, cycle time, and the assigned by means of work measurement enable to
number of workstations, and thus increasing its minimize time loss and increase efficiency [12]. For these
complexity [5]. However, assembly lines are used reasons, the standard time is calculated and used in every
extensively in mass production systems to produce high firm. Standard time is the total time for finalizing an
quantity standardized products [6]. Assembly lines are operation along with the standard performance [13]. The
classified according to the number of models and products

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time study method most widely used in companies is the throughput, and evaluating the impact of each item in the
stop watch technique [14]. product mix. Simulation approaches were also used in
Despite the fact that research on assembly line workforce scheduling used the discrete event simulation
balancing dates back to more than a century, it is still of (DES) model in planning a job-shop environment by using
interest to many researchers. This is because assembly line Arena simulation software [20].
balancing problem (ALBP) is directly related to Simulation is a scientific method to separately
production efficiency. Number of methods has been study a system without actually disconcerting it, but also
introduced by researchers to improve productivity in to assess ideas that have not been used in the real world
garment industries. Some techniques deal with specific [21]. Simulation is used to predict assembly line
problems such as inventory, quality lean manufacturing performance among other machine layouts and scheduling
and set-up time [15, 16]. Although a garment factory rules, thus find the best performing layout. Simulation
consists of several departments, the sewing department is modelling is mostly used to support decision-making in
the most important department in the whole firm. Because various commercial tasks [22]. The model simulations
a lot of different operations are carried out manually there offer data about the process results, performance and
by providing the scope for improvement. Line balancing is behaviour with diverse process structures [23].
one of the techniques that can be used to enhance the Manufacturing simulation approach is a set of
productivity in production lines. Job assignment to manufacturing policies planned to maximize performance
operators in a production line by means of a scientific among trade-offs among profit standards to meet the
approach is extremely important to maintain the manufacturing job determined by a corporate strategy
consistency of operating efficiency. [23].
Simulation is a technique used to imitate the This research paper focuses on using simulation
actual operations of a real system. It is used to help the method as a method to improve the line efficiency in a
decision-maker to understand the behaviour of the system garment factories considering real time data collected at
and implement necessary improvements. There have been work stations.
various studies conducted in various areas using
simulation approaches to solve problems in the 2. RESEARCH METHOD
manufacturing, food processing [17], transportation, health To compete with growing international demand,
care [18], military and other industries. smart productions are needed. They are facilitated by
Simulation has become a widespread technique in integrating the physical work environment and virtual
assessing the impact of decisions made in any sector. worlds [24]. The virtual environments can be developed to
Simulation techniques presently are widely used in replicate the real environments by simulation methods.
combination with operation research and artificial The integration is done by manual/automatic and
intelligence approaches in helping the decision-maker to offline/online data collection and feeding to the systems.
identify the problems in the system and evaluate various For this, internet networking concept, sensors are used to
alternatives for system improvements before making capture the data. Data is installing into the database at the
decisions. machine before transmitting to server through intranet. By
In the manufacturing industry, simulation has using MySQL commands, these data are compiled and
been widely used to solve many problems such as resource coding to align the simulation requirement inputs. This is
planning, worker scheduling, material handling process, the main basic of networking system towards Industry 4.0.
performance improvements, and others. Production By doing so, all physical devices can be connected to the
enhanced scheduling procedures using a simulation Internet. The proposed model driven decision support
approach in pharmaceutical companies with large product system (MD-DSS) provide a compressive and effective
mixes [19]. They assessed the performance of a schedule framework on how assembly line data can be simulated for
by measuring resource utilization, identifying bottlenecks, proper decision making is illustrated in Figure-1.

Figure-1. Proposed model driven decision support system (MD-DSS) framework.

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Step 1: Collecting Data: Data is gathered through relations, bundle sizes, job release policy, machine type,
conducting time study measurements. Data collection and production target. While the output variables from the
methods used is physical observations, document studies, Arena model included cycle time, idle time, resource
and time study measurements with the help of sensors utilization, throughput, defect, and work in progress
placed on the sewing machines. 30 readings for every (WIP). WIP was adopted to determine the global best line
operation/task were taken over a period of 3 days. In this balancing condition.
study, data were collected using a web-based program,
where PHP language, web-based database MySQL, and 2.1 Construction of Computer Model
web serve provider Linux are used. The PHP + MySQL In the construction of computer model or base
platform is a famous database-driven web service that model, several Arena simulation elements were used
facilitates the proposed framework. The sensors at the including entity, variables, resources, process, attribute,
machines are used to collect data processes. A set of data and transfer and control logic elements. The following
retrieved by sensors before transmitted to MySQL model assumptions were used for simulation model
database. With the help of intranet and SQL command, all development in this study:
required data from selected machines are compiled into
database MySQL. a) The input materials arrived in production line at
Step 2: Storing Data: Compiled data at database constant time, that is, every day and there was no
MySQL were aligned based on the simulation input such shortage of materials from cutting department.
as cycle time, number of machine/work stations, target b) There was no breakdown of the machines in the
quantity, number of operators etc. A simulation model is production line.
used to simulate the production system to figure out the c) There were no absenteeism of the operators and
real operation of the garment assembly system in the helpers, and so the workstations are never stopped due
production line. to absence of the operators or helpers.
Step 3: Simulation and Decision Making: d) Helpers were not allowed to operate any machine,
Simulation is a very helpful tool to assist in the decision- only operators are assigned to machines. Therefore,
making process to implement smart production concepts the numbers of operators were equal to the number of
related to Industry 4.0 at the existing assembly operation machines and increasing machine number also
[25, 26]. Models are developed similar with the existing increases operator number and vice versa.
production system. In addition to the garment assembly e) The daily production shift was 8 hours, and there was
processes, the related elements such us waiting times, lot no overtime considered.
sizes, minimum inventory quantity requirements, f) Infinite buffer (workstation’s bundles or workpieces
transportation times, standard times and precedence storage) capacity was considered which implies that
constraints are included in the model to enable the feel of the buffer at each workstation could never be full.
real assembly line.
In this research, to demonstrate the MD-DSS, 2.2 Simulation Method
discrete event simulation (DES) is used. This is a powerful In order to build a model of a complex trouser
tool to support organizations with the decision to assembly line, four separate simulation models were
implement lean manufacturing by counting the benefit developed and then combined as shown in Figure-2.
based on the specific situation [27]. Before decision
making, DES model created to estimate the system
capability for the optimal settings of decision variables.
The decision makers define the decision variables or
scenarios which can be changed based on their allowable
ranges.
The computer model of the skimmer trouser
assembly line was developed based on DES using Arena
Figure-2. Computer simulation model construction
simulation software (Academic License Version 14). The
approach for this study.
simulation model was built on a 64 bits ThinkPad
computer with a 3.00 GHz Intel core i7 CPU and 16.00
Part preparation (PP) module consists of nine
GB RAM. Although the processing speed of the think pad
sub-operations; the front part preparation (FP) module
computer is high, 32 bits Arena software category was
consists of six sub-operations; the back part preparation
well-suited to be installed instead of the 64 bits.
consists of four sub-operations; and the assembly
Consequently, the simulation model was developed and
operation (AO) consists of fifteen sub-operations. The
run smoothly without freezing the computer. For the
precedence relationship between the operations is shown
computer model construction, the following model input
in the Figure-3.
were used. They are-the processing times, number of
machines, number of operators, number of tasks, number
of helpers, quantity of input material per day, inter-arrival
time of parts, productivity per day, working hours,
quantity of input materials per day, task precedence

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Process module was used to model the working

of resources (machines, helpers, quality personnel) in
completing the given tasks. In fact, each process module
was used to represent the one resource at each
workstation. This implies that total process modules used
were equivalent to the total number of the available
resources in the trouser assembly line. Operator and
machine were modeled as single resource, but denoted as
machine of different types.
Decide module was used to make decision on
bundles or workpieces distribution to the resources in the
Figure-3. Precedence relationship of the operations. same workstation. It was also used to model the task
assignment pattern to operators whether equal workload or
The construction of simulation models with unequal workload on the operators performing similar
Arena, involved using modeling shapes called module- tasks, moreover, it was used to decide on quality whether
from the basic process, advanced process, and advanced rework required or not.
transfer panels. These modules are used as the building Hold module was used to model job release
blocks in developing a simulation model. There are two policy based on the work in process (WIP) threshold of the
types of modules- data module and flowchart module. bottleneck workstation. It holds the bundles generated by
Data modules (resource, queue, variable, schedule, and the create module and only releases some bundles
set) are user to manipulate in the spreadsheet interface, restricted by the set WIP threshold of the bottleneck
which are not placed in the model window. While, the workstation. The bottleneck workstation is the one whose
flowchart modules are used in model window to connect capacity is less than the demand placed on it and less than
data modules to form a flowchart, which describes the the capacities of all other resources. WIP is the number of
logic of model. In the present study, the flowchart modules unfinished bundles or workpieces in the workstations.
from three Arena project bars were utilized: basic process Match module was employed to combine two or
(create module, batch module, separate module, assign different parts bundles to a workstation. In addition, four
module, record module, process module, and decide Arena models developed were combined using match
module), advanced process (hold module and match module to form a full trouser assembly line model. By
module), and advance transfer (station module and route using match module, all trouser parts bundles and
module). workpieces were captured, and in case of missing parts,
The Arena flowchart modules used in this study there could be no trouser output at end of the assembly
were as follows: line.
Create module was used to mimic the trouser Station and Route modules are complementary
parts bundles’ arrival from the cutting department to the modules of advance transfer. They were used to replace
assembly line. The number of Arena create modules used the modules connecting links which eliminated the
were (six) equal to the number of operations on the congestion of the simulation model.
trousers that do not have precedence operations. Dispose module was used as the exit for finished
Batch module was used to combine individual cut trousers at end of the assembly line.
pieces into bundles to be moved to the next operators. All these Arena modules played great roles in
Specifically, batch operation is used to make the computer building simulation model of the complex trouser
understand that the operation can only be performed when assembly line. The line diagram of complex trouser is
all precedence operations are performed. presented in Figure-4. Basically, developing a simulation
Separate module was used to separate the bundles model involved identifying one or more flow objects
of workpieces to be seized and released as a single known as entities that flow through the system and then
workpiece by the operators. building a flowchart of the model using Arena’s flowchart
Assign module was used to add attributes names, modules. In the simulation of trouser assembly line, the
pictures, and variables to the entities (trouser parts bundles bundles arrive in the line with the inter-arrival time of 8
or workpieces). hours, the bundles were held at the bundle arrive table
Record module was employed to count the using hold modules, which were then transferred to the
throughput at end of part preparation, front preparation, specific workstations using the route and station modules.
back preparation modules and the full assembly line.

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Figure-4. Line diagram of the trouser.

The actual model constructed and used for consistency and repeatability of the results. The
simulation in Arena software is show in the Figure-5. The simulations model is constructed following the precedence
initial measured readings of all the 34 operations are given relationship among the operations. The results of the
as input for the simulation. The input analyzer is used to simulation model- with utilization time in minutes,
generate the distributions of the standard times and the instantaneous utilization in initial scenario and proposed
distribution type which best fit the data along with the simulation model along with percentage improvement in
squared error is presented in the Table-1. The expression instantaneous utilization of each work station is shown in
from the input analyzer are given as the input for the the Table-2.
simulation model and the model is run 30 times for

p a r t p r e p a r oi1 n P a n e l o v e r ol c k 1 0 Z pi p e r a t t a c h w ti h 1 2 D o u b el f yl a t t a c h
Ba t c h 2 1 1 J s t ci h w ti h p a n e l
panel
0
0 0
0 0 0

p a r t p r e p a r a r oi n 2 2 D o u b el f yl
Ba t c h 3
1 3 P pi ni g 14 Cr o t c h 1 5 T a c k ni g
0
0
0 0 0 0
B a t c h 41 Z pi p e r a t t a c h w ti h
d o u b el f yl

p a r t p r e p a r a t oi n 3 0 0
3 S ni g el f yl
0
0 B a t c h 2 05 I n s e a m o2v 1e r I nol soek a m t o p s t ci h
2 2 S di e s e a m2 3 S di e o u t nil e 2 4 R u n s t ci h

0 0 0
p a r t p r e p a r oi 5n F4 a c ni g o v e r ol6 c kW a si t b a n d h o el 0 0 0

0
0 0 B a t c 2h 5 6 W a si t b a n d 2 a6 t tC ao cr hn e r d o w n
2 7 C o r n e r t o2 p8 B a r t 2a 9c k L o o p b3a0r Bt oat c t ko m h3e1m Bmo t ni t go m c h3 a2 ni B e tl ol o p3 3 K e y h o el 3 4 K e y s e w ni g D si p o s e 1
t o panel s t ci h
0 0
8 W a si t b a9 n dW a si t b a n d al b e l 0 0 0 0 0 0 0 0 0
p a r t p r e p a r 7oi n P o5 c k e t b a g a t t a c h at t ach 0
bot t om
0
0 0 0

16 Bac k pocket
b a c k p a r t p r e p e r a t oi n 1 7 B a c k y o k e 1 8 B a c k r a si e1 9 B a c k al b e l a t t a c h
a t t a c h w ti h p a n e l
0
0 0 0 0

Figure-5. Actual simulation model constructed using Arena software.

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Table-1. Input analyser details.

No. Distribution Type Square Error No. Distribution Type Square Error
1 Lognormal 0.028663 18 Erlang 0.034774
2 Normal 0.018783 19 Gamma 0.039749
3 Weibull 0.044541 20 Normal 0.113473
4 Beta 0.060581 21 Normal 0.018896
5 Erlang 0.051806 22 Exponential 0.046841
6 Weibull 0.006341 23 Erlang 0.011245
7 Erlang 0.012415 24 Weibull 0.004709
8 Normal 0.035185 25 Gamma 0.021644
9 Normal 0.039306 26 Normal 0.038127
10 Normal 0.014565 27 Weibull 0.030429
11 Lognormal 0.009664 28 Normal 0.047586
12 Lognormal 0.030618 29 Beta 0.009170
13 Lognormal 0.005908 30 Gamma 0.023604
14 Lognormal 0.008353 31 Erlang 0.015350
15 Gamma 0.068916 32 Exponential 0.026832
16 Weibull 0.026514 33 Lognormal 0.002838
17 Lognormal 0.021094 34 Beta 0.022056

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Table-2. Results of simulation method.

Total Instantaneous Instantaneous

Work Utilization Utilization Percentage
Utilization
Station Improvement
time (min) Initial scenario Simulation
1 64 0.133 0.1461 9.85
2 104 0.217 0.226 4.15
3 48 0.100 0.12 20.00
4 88 0.183 0.2123 16.01
5 80 0.167 0.199 19.16
6 80 0.167 0.2886 72.81
7 96 0.200 0.2258 12.90
8 144 0.300 0.3461 15.37
9 144 0.300 0.334 11.33
10 216 0.450 0.5021 11.58
11 208 0.433 0.5057 16.79
12 208 0.433 0.4627 6.86
13 280 0.583 0.6643 13.95
14 248 0.517 0.5643 9.15
15 224 0.467 0.5226 11.91
16 344 0.717 0.793 10.60
17 128 0.267 0.3007 12.62
18 192 0.400 0.4413 10.33
19 224 0.467 0.5181 10.94
20 208 0.433 0.4661 7.64
21 280 0.583 0.6322 8.44
22 304 0.633 0.7011 10.76
23 264 0.550 0.5991 8.93
24 456 0.950 0.9987 5.13
25 256 0.533 0.4463 -16.27
26 256 0.533 0.5887 10.45
27 264 0.550 0.6178 12.33
28 288 0.600 0.6677 11.28
29 264 0.550 0.6083 10.60
30 304 0.633 0.6899 8.99
31 312 0.650 0.7041 8.32
32 256 0.533 0.5833 9.44
33 120 0.250 0.2829 13.16
34 56 0.117 0.1421 21.45

3. RESULTS AND DISCUSSIONS system is implemented. The results of the percentage

The garment assembly line’s productivity is utilization of all the work stations are tabulated in the
checked in the initial scenario and results are tabulated in Table-2. The initial result shows a prominent improvement
Table-2. The same data is feed to Arena software for in the utilization of the work stations as shown in the
simulation and the proposed model based decision support Figure-6. The percentage utilization increased for all the

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work stations except for the work station number 25, [3] A. Akdogan and A. S. Vanli. 2020. Introductory
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Operations Management. New Age International.
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