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.