Journal of Textile Research ›› 2020, Vol. 41 ›› Issue (02): 125-129.doi: 10.13475/j.fzxb.20190104905

• Apparel Engineering • Previous Articles     Next Articles

Balancing optimization of garment sewing assembly line based on genetic algorithm

ZHANG Xujing, WANG Lichuan, CHEN Yan()   

  1. College of Textile and Clothing Engineering, Soochow University, Suzhou, Jiangsu 215021, China
  • Received:2019-01-22 Revised:2019-06-28 Online:2020-02-15 Published:2020-02-21
  • Contact: CHEN Yan E-mail:yanchen@suda.edu.cn

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Abstract:

In order to solve the problem of efficiency loss caused by the imbalance of the garment sewing assembly line, an optimization goal was established to minimize the balance loss rate. The genetic algorithm was used to obtain the result. The men's shirt assembly lines of three kind of workstation layouts (the order of processes, the type of machines and the components of garment) were taken as examples for application. The results show that there are 14 workstations in the assembly lines where the workstations are arranged according to the processes and machines. There are 15 workstations in the assembly line that the workstations are arranged according to the garment components. And the number of operators and machines required are more than the other two kinds of workstation layouts. The time loss rate of the workstations arranged according to the processes is 8.74%. The time loss rate of the workstations arranged according to the machines is 11.79%. And the time loss rate of the workstations arranged according to the garment components is 20.32%, but it is still higher than the lowest line of the enterprise. It can be seen from the simulation model that the optimized assembly lines of three workstation layouts can be applied to actual production, which can effectively reduce the production cost of the enterprise.

Key words: genetic algorithm, sewing assembly line balancing, workstation layout, men's shirt, time loss rate

CLC Number: 

  • TS941

Fig.1

Flow chart of genetic algorithm"

Tab.1

Men's shirt process sheet"

工序编号 工序名称 工序设备 作业时间/s
1 扣门襟贴边 电蒸汽熨斗 20
2 锁门襟扣眼 锁眼机 10
3 钉扣 钉扣机 14
4 折口袋 折口袋机 30
5 钉口袋 平缝自动剪线机 27
6 剪扣商标 商标剪扣机 2
7 剪扣尺寸标牌 商标剪扣机 2
8 钉商标尺寸标牌 平缝自动剪线机 25
9 绱过肩 平缝自动剪线机 22
10 合肩 平缝自动剪线机 20
11 拼接袖衩 平缝自动剪线机 10
12 绱袖衩 平缝自动剪线机 18
13 烫袖子 多用烫衣机 10
14 绱袖子 五线包缝机 21
15 剪扣洗涤标牌 商标剪扣机 2
16 钉洗涤标牌 平缝自动剪线机 20
17 合袖底侧缝 五线包缝机 30
18 窝底边 平缝自动剪线机 22
19 黏翻领衬 电蒸汽熨斗 18
20 熔解黏合衬 黏合机 5
21 夹领尖 高速带刀平缝自动剪线机 20
22 翻领尖 翻领机 10
23 烫领尖 领角定型机 20
24 熨烫翻领 电蒸汽熨斗 12
25 缉翻领明线 平缝自动剪线机 18
26 翻领定型 衬衫圆领机 6
27 剪翻领 上下切领机 10
28 黏底领衬 电蒸汽熨斗 7
29 缉底领明线 平缝自动剪线机 8
30 合领子 平缝自动剪线机 16
31 翻烫底领 电蒸汽熨斗 18
32 缉底领上口明线 平缝自动剪线机 6
33 净底领 切底领机 7
34 点领子三眼 手工台 10
35 绱领子 平缝自动剪线机 20
36 缉领子下口明线 平缝自动剪线机 40
37 黏袖克夫衬 电蒸汽熨斗 30
38 勾袖克夫 平缝自动剪线机 16
39 扣袖克夫 电蒸汽熨斗 10
40 翻烫袖克夫 定型压烫机 15
41 缉袖克夫上口明线 平缝自动剪线机 10
42 缉袖克夫明线 平缝自动剪线机 12
43 锁袖克夫扣眼 锁眼机 8
44 钉袖克夫扣 钉扣机 10
45 绱袖克夫 平缝自动剪线机 40
46 翻袖子 手工台 7
47 锁领头扣眼 锁眼机 15
48 钉领头扣子 钉扣机 12

Tab.2

Optimization results of genetic algorithm"

工作地
布置方式		 种群数50,迭代次数200 种群数80,迭代次数500 种群数100,迭代次数500 种群数100,迭代次数800
工作地数量 时间损耗率/% 工作地数量 时间损耗率/% 工作地数量 时间损耗率/% 工作地数量 时间损耗率/%
工序流程 25 25.71 18 15.85 14 8.74 14 8.74
工艺种类 25 26.89 19 18.61 14 11.79 14 11.79
服装部件 28 32.75 22 24.45 15 20.32 15 20.32

Tab.3

Assembly line balancing schemes for different workstation layouts"

工作地
编号		 工序流程 工艺种类 服装部件
工序
编号		 加工时
间/s		 设备
数量/台		 工序
编号		 加工时
间/s		 设备
数量/台		 工序
编号		 加工时
间/s		 设备
数量/台
1 1,37,6,7,15 56 2 5,41,21 57 2 5,8 52 1
2 2,43,47,27,33 50 3 18,35,42 54 1 1,3,9 56 3
3 3,44,48,22 46 2 25,36 58 1 2,4,6,7 44 3
4 4,19,46 55 3 10,11,38 46 1 23,26,27,29 44 4
5 5,9 49 1 29,45 48 1 19,31,22,33 53 3
6 8,11,18 57 1 9,12,16 60 1 21,24,28,34 49 3
7 10,12,16 58 1 8,30,32 47 1 20,25,30,32 45 2
8 14,17 51 1 19,37,34 48 2 37,41,43 48 3
9 13,20,23,26,40 56 5 4,24,28,39 59 2 12,38,42,39 56 2
10 21,30,38 52 2 1,31,6,7,15,46 51 3 11,13,40,44 45 4
11 24,28,31,39,34 57 2 2,43,47,22 43 2 35,36 60 1
12 25,29,32,35 52 1 14,17 51 1 18,45 62 1
13 36,41 50 1 3,44,48,27,33 53 3 14,16,46 48 3
14 42,45 52 1 13,20,23,26,40 56 5 10,15,48 34 3
15 — — — — — — 17,47 45 2

Tab.4

Objective values for different workstation layouts"

工作地布置方式 时间损耗率/%
未优化 74.27
工序流程 8.74
工艺种类 11.79
服装部件 20.32

Tab.5

Simulation results of assembly lines with different workstation layouts"

工作地布置方式 日产量/(件·d-1) 设备平均利用率/%
未优化 482 36.9
工序流程 488 82.8
工艺种类 490 90.6
服装部件 519 88.3
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