Journal of Textile Research ›› 2020, Vol. 41 ›› Issue (07): 154-159.doi: 10.13475/j.fzxb.20190707706

• Apparel Engineering • Previous Articles     Next Articles

Garment production line balance based on genetic algorithm and simulation

HUANG Zhenzhen1,2(), MOK Pikyin3,4, WEN Lihong1   

  1. 1. Clothing and Design Faculty, Minjiang University, Fuzhou, Fujian 350108, China
    2. Fujian Clothing Industry Technology Development Base, Fuzhou, Fujian 350108, China
    3. Institute of Textiles & Clothing, The Hong Kong Polytechnic University, Hong Kong 999077, China;
    4. Shenzhen Research Institute, The Hong Kong Polytechnic University, Shenzhen, Guangdong 518000, China
  • Received:2019-07-31 Revised:2020-04-13 Online:2020-07-15 Published:2020-07-23

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Abstract:

The low production efficiency and the long production cycle are among the common problems in the clothing industry. A method for balancing the production line with automatic workstation scheduling and production simulation was proposed. By analyzing the influencing factors for balancing the garment production line, the garment production model using topology model and genetic algorithms was developed to optimize the production schedule using MatLab (R2016b). Based on the optimized schedule, simulation technology was adopted to further improve the flow balance, considering the order quantity and equipment status. The production flow was simulated according to actual production line formulation using the Plant Simulation software. Quantitative and visual simulation results were obtained, supporting the re-optimization of the production flow balance. The proposed method was verified with real production data. An efficiency of 90.8% was achieved for experimental production line, representing a 12.8% improvement comparing with the actual production data. It shows that the proposed method can shorten the production cycle, and it provides ideas for the development of the garment production flow optimization and simulation system.

Key words: garment production line, production process arrangement, genetic algorithm, production line balance, production line simulation

CLC Number: 

  • TS941

Fig.1

Optimization algorithm for garment production line balance"

Fig.2

Dress sketch. (a) Front details; (b) Back details"

Fig.3

Flowchart for skirt manufacturing"

Fig.4

Workstation scheduling"

Tab.1

Restructured workstation scheduling"

工位编号 工序编号 节拍/s 设备 工位编号 工序编号 节拍/s 设备
A 4、10、11 94.92 四线锁边机、五线锁边机 G 15 108.00 平缝机
B 5、12 94.54 平缝机 H 16 104.73 五线锁边机
C 1、6 75.38 平缝机 I 2、17 58.91 四线锁边机
D 3、14 98.18 绷缝机、平缝机 J 18~26 122.18 平缝机
E 7、8 93.8 四线锁边机 K 18~26 122.18 平缝机
F 9、13 91.55 平缝机 L 18~26 122.18 平缝机

Fig.5

Simulation model for production flow"

Fig.6

Dynamic chart for production flow simulation"

Fig.7

Pitch time of work stations"

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