Bottleneck and Assembly Line Balancing in Garments Production

Line balancing implies balancing the production line or any assembly line. The principle goal of line balancing is to circulate the errand over each work station so that the inert time of the work of the machine can be minimized. Assembly Line Balancing is the key to be a line productive and efficient with a smooth flow.

Line balancing targets gathering the assets or work in an efficient and best example so as to get an idea or then again appropriate parity of the assets and streams of the production or assembly forms.

Assembly Line Balancing (ALB) is the term usually used to allude to the choice procedure of delegating assignments to workstations in a succession approach to production framework.

The assignment of essential activities required to manufacture crude material into the completed item.

The rise of quick changes in style has offered to ascend to the need to abbreviate production process durations in the piece of the clothing industry. 

As powerful use of assets significantly affects productivity, what’s more, proficiency in production activities, article of clothing producers are encouraged to use their assets successfully so as to satisfy dynamic client needs.

This paper centers explicitly around line balancing and layout modification. The point of assembly line balance in sewing lines is to dole out assignments to the workstations so that the machines of the workstation can play out the doled out assignments with a reasonable stacking.

Remark Bottleneck Operation:

The bottleneck is the brother of  Line balancing. Before about line balancing we have to go bottleneck operation. Then need work measurement tools to remark the bottleneck operation. It is very important for a line on the production floor. Bottleneck indicates the lowest outcome of the operation in a line.

Example:
 
Operation name                   Output
1) Side seam                        70 pcs
2) Back rise                          60 pcs
3) Inseam                             50 pcs
4) Bottom hem                     40 pcs
5) J STC                                 60 pcs
 
Hence, The bottom hem is the bottleneck operation.
 

The power of Assembly Line Balancing

To improve the productivity of the line we have to remove bottleneck operation by balance the line. That means how many operators will be provided for balancing the line. 
The main goal of this study is to ascertain how lean manufacturing (LM) practices affect layout facility designing and line balancing.
A severe case study was conducted specifically in the garments sewing section. At the very beginning, a detailed work measurement of their existing Sewing process and layout study was conducted.
The paper addresses to solve the assembly line balancing with different labor skill levels to reduce in-process inventory and workload smoothing in the workstations of sewing. 

Basically Assembly Line Balancing medicates the manpower allocation for each operation.


Our Case study :     

No. of workers = 14
Line hourly Target = 58 pcs 

                  

Operation        Individual       Hourly Target       Man Allocated
1.                     105 Cm            57 Pcs                            1
2.                     100 Cm            60 Pcs                            1
3.                     95 Cm              63 Pcs                            1
4.                     110 Cm            54 Pcs                            1
5.                     210 Cm            28 Pcs                            2
6.                     200 Cm            30 Pcs                            2
7.                     100 Cm            60 Pcs                            1
8.                     95 Cm              63 Pcs                            1
9.                     101 Cm            59 Pcs                            1
10.                   100 Cm            60 Pcs                            1
11.                   105 Cm            57 Pcs                            1
12.                   100 Cm            60 Pcs                            1
Garment SMV = 14.21 Min.
 
 
                                                                                                   Different type of machine
                                                                                                   Different type of thread
                                                                                                   Different type of presser foot
                                                                                                   Different types of skilled workers.


The production line is redesigned to shape a lean line with an optimum layout which results basically in the productivity improvement. The territory of the present layout was resolved and the modification of the machines in the layout so that there is a lessening in the region. The machines are kept in a solitary straight line as indicated by the activity succession.

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