U-shape layout of sewing assembly line in apparel industry

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Multi-objective optimization formulti-line and U-shape layout of sewing assembly line in apparel industry

The design of assembly line layout is one of the most important influential factors forthe company's performance.Theinappropriate arrangement of the order of workstations in the assembly line could cause the excessive movement of the material. In order to increase productivityand reduce production cost, a multi-objective optimization model with minimum the transfer distance of semi-finished products and the total area of assemblylinewas established in this paper. The Non-dominated Sorting Genetic Algorithm-II was applied to obtain the results of this model. The coding method, genetic operation and fitness function for three different kinds of sewing assemblylinelayouts (multi-line, U-shape two-line and U-shape three-line) were studied, while the workstations were organized in three ways: the order of processes, the type of machines, and thecomponents of garment. The efficiency of the model was verified by the practice of sewing assembly lines for men's shirt. The layout schemes are compared with other algorithms. https://vssewingmachine.in/ The results illustrated that NSGA-II algorithm is an effective tool to solve the sewing assembly line layout problem. 
 The transfer distances of semi-finished products in the multi-line and U-shape (three-line) layouts arranged by garment componentsworkstation layout were short. The multi-line layout arranged bythe type of machinesworkstation layout occupied the smallest area. The modelis suitable for solving the layout problem of the garment sewing workshop in practice, shortening the production cycle, and reducing the production cost.A variety of assembly line layout schemes are provided for apparel manufacturers in this paper. Apparel manufacturers can selectthe appropriate assembly line layout based on the actual conditions ofthe workshop and product.
With the rapid development of society, the demand ofclothing products is more diversified. In order to quickly respond to the demands of multi-variety, small batch and short-cycle production, and effectively improve the production efficiency, the role of workshop logistics planning and layout in manufacturing system has become increasingly prominent[1]. The reasonable assembly line layout andlogistic route improvethe operation efficiency, production quality andreduce costs. The reasonable layout of assembly line can reduce the waste rate of production space,increase the utilization rate of the workshop area andexpand theproduction scale. Thereasonable planning of the logistics route can effectively shortenthe transferdistance of semi-finished products, reduce the logistics cost, and improve the production efficiency of the workshop[2]. However, in practice, the assembly line layout is usually arranged based on the subjective experience of technicians. This empirical layout scheme hassome disadvantages such aspoor adaptability and low fluency of semi-finished products operation. 
 It may result in low production efficiency and high production logisticscost, thus reducing the economic benefits of enterprises [3].In the garment production process, most semi-finished products are in a state of stagnation or transfer, only5% of the time is used for processing the semi-finished products. 20%-50% of operating expenses are used for handlingand storage of semi-finished products [4]. VS Enterprises In addition, such as oil stains, chromatic aberrations, etc., may be caused during the stagnation and transferof semi-finished products [5]. The transferof the semi-finished productsrequires time and operators. Reasonable arrangement of the semi-finished product transferroutescan shortenthe transfertime,improve the production efficiency and the output [6].The transfer of semi-finished products ingarment sewing assembly line is complicated. There are great differences between the assembly lines based on the different organizationalmodels. In order to improve the operationefficiency of semi-finished products in the sewing assembly line, it is very meaningful to study the layout of assembly line according to the actual situation of enterprises. Generally, the assembly line layout can be divided into the five forms according to the arrangement shape and the flow pattern of semi-finished products.(1) Straight layout is to arrange the workstations ina straight line, so that the semi-finished products transferalong the straight line from the first workstation during processing. But straight layout space is often narrow. It is suitable for assembly lines thatthe production process is short and simple,or thenumber of processes and machinesis small.(2)U-shape layout is to arrange the workstations according to the processing order, so that the logistics route is U-shape. This kind of layout is more compact and suitable for production workshops with small length and width.(3) S-shape layout refers to the arrangement of workstations along the S-shape of logistics. Itcan be used to arrange longer processassembly line layouts in a larger shop area, such as automotive assembly line.(4) The circularlayout is to arrange the workstations along the circularshape. This layout is suitable to produce finished products thatneed to be returned to the starting point.(5) Multi-line layout means that the workstations are arranged in multi lines. Semi-finished products can be transferredbetween different workstations perpendicular to the line oralong the line. This layout can save the workshop space and the semi-finished products transferpaths are flexible. It is mainly applied to the assembly line layout with various kinds of processing products and complex processes.There are many kinds of processes and machines involved in garment sewing assembly line. The multi-line layout, U-shape (two-line)layout and U-shape (three-line)layout of garment sewing assembly line are discussed in this researchaccording to the characteristics of assembly line layout.In general, production process of garment is relatively long, which also affects the transferdistance of semi-finished products. Fortunately,the workstations can be arranged reasonably by three different layouts based on production cycle. The order of processes workstation layout (PWL) is to arrange the workstations according to the processing order, as shown in Fig.1(a).The type of machines workstation layout (MWL) is that machines required for the same processing contents are arranged in sameworkstation, as shown in Fig.1(b).And the components of garment workstation layout (GWL) is to produce each garment component asa workstation, as shown in Fig.1(c).
In this paper, the layout model of the apparel assembly line was analyzed bythe practice of men’s shirtmanufacturing. The NSGA-II algorithm (Non-dominated Sorting Genetic Algorithm-II) algorithm was applied to obtain the layout schemes of different sewing assemblylines. The optimum way of the sewing assembly line in different workstation layouts could be found according to the results obtained from the model calculation. This paper wasorganized as follows: The assumptions, constraints and objective functions of the assembly line layout model were described in Section 2. The NSGA-II algorithm design was specifically described in Section 3. The men's shirtassembly line was usedas an example, the different assembly line layouts fordifferent workstations layouts and wereoptimized. Each optimization scheme was compared to each other to select an effective solution. A detailed experimental design and results were presented in Section 4. Discussion wasillustrated in Section 5. In Section 6, several conclusions were summarized.
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