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A Complex Garment Assembly Line Balancing Using Simulation-based Optimization
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  • OCIDENT BONGOMIN,
  • Josphat Igadwa,
  • Eric Nganyi,
  • Ildephonse Nibikora
OCIDENT BONGOMIN
Moi University
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Josphat Igadwa
Moi University
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Eric Nganyi
Moi University
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Ildephonse Nibikora
Busitema University
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Abstract

The nascent wave of disruptive competition in the current business environment brought about by the fourth industrial revolution (Fashion 4.0 or Apparel 4.0) is enormous. Therefore, it is paramount important to apparel industry to be flexible enough to respond quickly to the unstable customers’ demand through continuous improvement of their process efficiency and productivity. This study aims at achieving an optimal trouser assembly line balancing using simulation-based optimization via design of experiment. The empirical study is conducted at Southern Range Nyanza Limited (NYTIL) garment facility and a complex trouser assembly line with 72 operations is considered. The discrete event simulation of the trouser assembly line is developed using Arena simulation software. The local optimal solution is obtained from simulation experimentation and is adopted for the optimization process. The OptQuest tool is utilized to solve a single objective function (throughput) optimization problem. The results show that average throughput increases from the existing design (490 pieces per day) to local optimal design (638) and global optimal design (762). Consequently, the line efficiency increases from 61.2% to 79.7% to 95.2% respectively. The high increase in line efficiency and average throughput confirms the suitability assembly line balancing using simulation-based optimization via design of experiment.

Peer review status:Published

27 Apr 2020Submitted to Engineering Reports
28 Apr 2020Submission Checks Completed
28 Apr 2020Assigned to Editor
30 Apr 2020Reviewer(s) Assigned
09 Jun 2020Editorial Decision: Reject & Resub
17 Jun 20201st Revision Received
18 Jun 2020Submission Checks Completed
18 Jun 2020Assigned to Editor
18 Jun 2020Reviewer(s) Assigned
13 Jul 2020Editorial Decision: Revise Minor
15 Jul 20202nd Revision Received
15 Jul 2020Submission Checks Completed
15 Jul 2020Assigned to Editor
15 Jul 2020Editorial Decision: Accept
03 Sep 2020Published in Engineering Reports. 10.1002/eng2.12258