基于技能熟练度的服装流水线仿真优化及其应用

doi:10.13475/j.fzxb.20240106001

纺织学报 ›› 2025, Vol. 46 ›› Issue (01): 169-178.doi: 10.13475/j.fzxb.20240106001

基于技能熟练度的服装流水线仿真优化及其应用

黄小源¹, 王青云², 侯珏²^,³, 杨阳²^,³, 刘正³^,⁴()

1.浙江理工大学纺织科学与工程学院(国际丝绸学院), 浙江杭州 310018
2.浙江理工大学服装学院, 浙江杭州 310018
3.丝绸文化传承与产品设计数字化技术文化和旅游部重点实验室, 浙江杭州 310018
4.浙江理工大学国际时装技术学院, 浙江杭州 310018

收稿日期:2024-01-30 修回日期:2024-09-11 出版日期:2025-01-15 发布日期:2025-01-15
通讯作者: 刘正(1981—),男,教授,博士。主要研究方向为数字化服装技术。E-mail:koala@zstu.edu.cn。
作者简介:黄小源(1997—),女,博士生。主要研究方向为数字化服装技术。
基金资助:
浙江省科技重点研发计划项目(2023C03181);嘉兴市重点研发计划项目(2023BZ10009)

Skill proficiency based simulation optimization of garment assembly line and its application

HUANG Xiaoyuan¹, WANG Qingyun², HOU Jue²^,³, YANG Yang²^,³, LIU Zheng³^,⁴()

1. School of Textile Science and Engineering (International Institute of Silk), Zhejiang Sci-Tech University, Hangzhou,Zhejiang 310018, China
2. School of Fashion Design & Engineering, Zhejiang Sci-Tech University, Hangzhou,Zhejiang 310018, China
3. Key Laboratory of Silk Culture Heritance and Products Design Digital Technology,Ministry of Culture and Tourism, Hangzhou, Zhejiang 310018, China
4. International Institute ofFashion Technology, Zhejiang Sci-Tech University, Hangzhou, Zhejiang 310018, China

Received:2024-01-30 Revised:2024-09-11 Published:2025-01-15 Online:2025-01-15

摘要/Abstract

摘要： 针对服装流水线人员编排不合理对生产效益产生的负面影响,以流水线平衡和提高生产效益为目的,提出了一种基于员工技能熟练度与仿真技术的流水线编排方法。采用实际生产数据量化员工技能熟练度评价指标,基于离差平方和的综合集成赋权法确定指标权重,建立技能熟练度评价模型,精确量化员工技能水平;通过员工技能配比系数构建流水线编排模型,提高流水线运行效率;再利用Flexsim工具进行模型仿真优化和评估,得到最佳流水线编排方案;最后,以休闲女裤为例进行生产编排的实例验证。结果表明:流水线编制效率可达93.77%,比考虑员工技能差异性的实际编排提高了6.05%。该模型可有效提高服装生产效益,为服装企业流水线编排提供新思路。

关键词: 服装生产, 服装流水线, 技能熟练度, 生产线仿真, 工序编排

Abstract:

Objective The apparel industry production model is gradually changing to a single-piece assembly line-based "small-order-fast" model, which requires highly coordinated use of human and equipment resources on the assembly line to maximize production efficiency. In assembly line production, there are differences in the ability of operators, and irrational assembly line staffing may result in wasted human resources and production bottlenecks. Aiming at solving the negative influence of unreasonable personnel arrangement on production efficiency, workers' skill proficiency should be considered as an important factor in assembly line scheduling. Therefore, a method of assembly line arrangement based on employee skill proficiency and simulation technology is proposed to balance assembly line and improve production efficiency.

Method In order to make full use of employees' skill proficiency for assembly line process scheduling, the actual production data were adopted to quantify the employee skill proficiency evaluation indexes and multilayer subjective assignment method and independence weight coefficient analysis were used for multidimensional weighting calculation. Based on the integrated assignment method of sum of squared deviations to determine the weights of the indexes, the skill proficiency evaluation model was established, which was adopted to accurately quantify the skill level of the employees. The assembly line arrangement model was then constructed through the coefficients of the employees' skill ratio to improve the efficiency of the assembly line operation. Flexsim tool was adopted to carry out the simulation optimization and evaluation of the model, so as to obtain the optimal arrangement plan for the assembly line. The example validation of the production arrangement was carried out by using the casual pants as an example.

Results The proposed model based on the degree of employee skill was simulated and the simulation results were compared with the actual output. The results of the two models for each station show that the processing time of the actual layout simulation model considering the difference of employees' skills is between 80.5% and 99.9%, with a wide fluctuation range. According to the optimized model, the fluctuation range of processing time is smaller, close to the average beat, and the optimized assembly line is more balanced, and the compilation efficiency is 93.77%, which is 6.05% higher than that actual arrangement considering the difference of employee skills.

Conclusion For the single-piece flow production line, employees' skill proficiency and simulation technology were combined to optimize the balance of apparel production line programming. Comparative validation using examples to show that the proposed method can meet the actual production requirements, and the compilation efficiency reaches 93.77%, which significantly improves the assembly line scheduling efficiency, proving the feasibility of scheduling optimization model based on the coefficient of staff skills matching. The method can provide a reference for experienced managers to adjust the process according to the skill level of employees, and can also provide a specific assembly line scheduling solution for new managers unfamiliar with the skill proficiency of employees.

Key words: garment production, garment assembly line, skill proficiency, production line simulation, process arrangement

中图分类号:

TS941

黄小源, 王青云, 侯珏, 杨阳, 刘正. 基于技能熟练度的服装流水线仿真优化及其应用[J]. 纺织学报, 2025, 46(01): 169-178.

HUANG Xiaoyuan, WANG Qingyun, HOU Jue, YANG Yang, LIU Zheng. Skill proficiency based simulation optimization of garment assembly line and its application[J]. Journal of Textile Research, 2025, 46(01): 169-178.

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链接本文: http://www.fzxb.org.cn/CN/10.13475/j.fzxb.20240106001

http://www.fzxb.org.cn/CN/Y2025/V46/I01/169

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一级指标	二级指标	专家1	专家2	专家3	专家4	专家5
作业情况	稳定程度	√	√	√	√	√
	作业速度	√	√	√	√	√
	合格率	√	√	√	√	√
技能水平	作业动作规范	√	√		√
技能水平	可操作工序等级	√	√	√	√	√
员工基本情况	年龄			√	√	√
	文化程度		√	√	√
	工龄			√		√

工序难易等级	表示符号	常见工序针步类型
很难	A	绱驳、绱、夹缉等
较难	B	扪缉、明缉、明贴、绲边、卷边、走封等
一般	C	拼合、暗缉、折缉、走定、走缩、烫定、包烫等
简单	D	拷边、烫倒、扣烫折烫、走定、刀车修剪等
容易	E	缩烫、模板机合缝、手工修剪、手工点位等

总目标	一级指标	二级指标
员工技能熟练度评价U	作业情况U₁	稳定程度U₁₁
	作业情况U₁	作业速度U₁₂
	技能水平U₂	合格率U₁₃
	技能水平U₂	可操作工序U₂₁

评价指标	主观权重 W_s_i/%		客观权重			综合权重 W_i/%
评价指标	主观权重 W_s_i/%	复相关系数R	复相关系数倒数1/R	权重 W_o_i/%		综合权重 W_i/%
X₁	18.429	0.682	1.467	18.095	18.262
X₂	31.722	0.399	2.504	30.900	31.311
X₃	27.794	0.414	2.417	29.817	28.806
X₄	22.055	0.582	1.717	21.188	21.621

工位编号	员工技能熟练度	技能配比系数
2^#	1.24	1.25
3^#	1.01	1.54
4^#	1.42	1.09
5^#	1.38	1.12
6^#	1.28	1.22
7^#	1.26	1.23
8^#	1.02	1.52
9^#	1.01	1.53
10^#	1.65	0.94
11^#	1.49	1.04
12^#	1.52	1.02
13^#	1.24	1.25

基于技能熟练度的服装流水线仿真优化及其应用

Skill proficiency based simulation optimization of garment assembly line and its application

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工位编号	作业工序	人数	加工时间/s	设备
1^#	分发裁片	1		分包台
2^#	8、14、25	1	158.9	单针电脑车
3^#	10、34、35、36	1	194.3	单针电脑车
4^#	5、6、7、9、11、 13、23、24、26、 28、33	1	224.5	烫台
5^#	27、29、30、37	1	200.7	单针电脑车、三线拷缝车、五线拷缝车
6^#	12、39、40	1	182.5	单针电脑车、三线拷缝车、单针配拉筒
7^#	1、3、4、22、 31、41、62、63	1	185.5	烫台
8^#	2、42、43、 60、61	1	217.8	单针电脑车、三线拷缝车、单针配拉筒
9^#	15、16、17、 18、46、47	1	209.8	单针电脑车、三线拷缝车
10^#	19、48、49、 50、51、52	1	152.1	单针电脑车、烫台
11^#	53、54、55、56	1	199.0	单针电脑车
12^#	57、59	1	199.3	单针电脑车
13^#	20、21、38、 44、45、58	1	184.5	单针电脑车
14^#	质检	1		质检台

编排模型	编制效率/%	总产量/件	平均日产量/件	与实际平均日产量差值/件
考虑员工技能差异性的实际编排仿真模型	87.72	1 529	192	-3
基于员工技能配比系数编排仿真优化模型	93.77	1 683	210	15

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