Journal of Textile Research ›› 2025, Vol. 46 ›› Issue (01): 169-178.doi: 10.13475/j.fzxb.20240106001

• Apparel Engineering • Previous Articles     Next Articles

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. 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 Online:2025-01-15 Published:2025-01-15
  • Contact: LIU Zheng E-mail:koala@zstu.edu.cn

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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

CLC Number: 

  • TS941

Fig.1

Process of establishing skill proficiency evaluation model"

Tab.1

Statistical table of factors affecting employees' skill proficiency"

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 √ √ √
可操作工序等级 √ √ √ √ √
员工基本
情况		 年龄 √ √ √
文化程度 √ √ √
工龄 √ √

Tab.2

Classification of process difficulty level"

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

Tab.3

Evaluation index of employee skill proficiency"

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
作业速度U12
技能水平U2 合格率U13
可操作工序U21

Tab.4

Weight calculation result"

评价
指标		 主观权重
Wsi/%		 客观权重 综合权重
Wi/%
复相关
系数R		 复相关系数
倒数1/R		 权重
Woi/%
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

Fig.2

Assembly line model based on skill matching coefficient"

Fig.3

Simulation and optimization model of assembly line arrangement based on employee skill matching coefficient"

Fig.4

Pants style chart. (a) Front; (b) Back"

Fig.5

Process sewing flow chart of casual pants"

Tab.5

Employee skill matching coefficient"

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

Fig.6

Process arrangement scheme before and after optimization"

Tab.6

Process allocation of casual pants before optimization"

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

Fig.7

Comparison chart of actual production time of simulation model employees"

Tab.7

Simulation model data comparison"

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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