Simulation for Garment Line Balancing
Simulation for Garment Line Balancing
Dept of Industrial, Manufacturing & Systems The Edward P. Fitts Department of Industrial and
Engineering Systems Engineering
The University of Texas at El Paso NC State University
500 West University Avenue Campus Box 7906
El Paso, TX 79968, USA Raleigh, NC 27695-7906, USA
ABSTRACT
The management of the production line is a challenging task due to the high level of uncertainty in demand,
which can lead to unbalanced utilization of resources. This may result in a potential deterioration of
management satisfaction in terms of cost-effectiveness. Therefore, it requires efficient tools to optimize
resource utilization. With such inherent needs, this paper presents a simulation-based decision support
framework for garments industries. The Discrete Event Simulation (DES) is used to model different
scenarios for the operational processes. The procedure focuses on the line balancing technique, which aims
to eliminate bottlenecks and optimize the production process by balancing the workload. The results of this
study demonstrate the effectiveness of the line balancing technique in improving line efficiency, reducing
the idle time of the operators, and increasing productivity. The simulation was developed using AnyLogic
simulation software. The outcome of the process is thoroughly evaluated and justified using a case study.
1 INTRODUCTION
The fast-changing consumer demand, international rivalry, the complexity of the supply chain, and
environmental concerns are just a few of the production issues that the ready-made garment (RMG)
industries must overcome. Rapid production cycles are needed to meet consumer demand for new fashions
and trends, which puts pressure on producers to lower prices and shorten lead times. Prices are lowered by
global competition, that imposes pressure on businesses to increase productivity and efficiency. It is
challenging to monitor and regulate quality in complex supply chains with numerous suppliers and
stakeholders, which results in production delays and increased prices.
In these circumstances, line balancing is a crucial step in the garment industry for increasing production
efficiency and lowering costs. It is the process of allocating the proper number of workers to each task on
a production line to prevent bottlenecks and delays. Manufacturers can boost output, cut down on lead
times, and enhance quality control by balancing the line. The optimal use of resources, equipment, and
labor makes resource optimization essential in the clothing industry. Manufacturers may decrease waste,
enhance product quality, and boost profitability by optimizing their resource use. Hence, it is impossible to
overestimate the significance of line balancing and resource efficiency in the clothing sector. To sustain in
a highly competitive market, producers need to be able to produce high-quality goods swiftly and
affordably. Manufacturers can attain these objectives and boost their bottom line by managing production
lines and utilizing resources to their fullest potential. Furthermore, customers and other stakeholders are
placing an increasing amount of value on resource efficiency and sustainability, thus it is crucial for
manufacturers to give these practices top priority to preserve their reputation and market position for their
business.
In the industrial sector, particularly in the ready-made garment industries, where production efficiency
and cost-effectiveness are critical, the idea of line balancing has grown in significance. By ensuring that
every workstation in the assembly line is used to its full ability and minimizing downtime and bottlenecks,
line balancing aims to optimize production operations. This project will investigate the use of AnyLogic
simulation software to enhance line balancing in the ready-made clothing sector. Due to the quick changes
in fashion, the configuration of the line must be updated regularly in the garment industry. To successfully
complete the line balancing operation, a comprehensive inspection of the entire system is required. But it
is quite difficult for a human to analyze actual production systems because of the fast overall process
development, the larger quantity of system variables, and as these components are stochastic. Also, it is
quite difficult to manually fix line balance problems while considering all the variables that may affect the
overall system’s performance. Several studies have been conducted to improve the production efficiency
of the ready-made garments industry as well.
Discrete event simulation (DES) is an effective tool for garments line simulation. Different writers tried
to solve problems in different manners. Güner et al. (2008) discussed how the simulation model helps
managers to prevent unexpected situations. An integrated simulation model is created that generates a set
of optimal production alternatives as well as a set of optimizing alternatives for a heavy continuous rolling
mill system in a real steel industry, Azadeh (2000). Besides that, Patel (2002) talked about the modeling
and research methods used to analyze the Final Process System of the vehicle manufacturing process and
create a productive and effective procedure to guarantee the system throughput. They have focused on
Process Layout, Testing station, and Repair stations where operators have the most impact on system
output. Choi et al. (2002) explained the first steps taken to deploy simulation modeling as a visual
management and analysis tool at a company that makes engine blocks for automobiles. A recent study was
observed in the related field by Halie et al. (2018) who outlined a simulation technique in an apparel
industry by using Arena software. For line balancing techniques, Talapatra et al. (2018) discussed how
production efficiency can be improved using Yamazumi Chart. The RMG sector must maintain the
warehouse system on their premises, and it incurs huge costs for supply chain works. Mustofa (2020) tried
to interpret how the bullwhip effect affects the performance of an industry. Through this analysis discussed
in the cement industry, Rahman and Shohan (2015) showed an approach to explain how cost evaluation
affects factory performance in terms of supplier selection which can be used to minimize cost factors in the
RMG industry. Sultana et al (2014) also explained how cost evaluation affects factory performance in terms
of supplier selection in two different processes and this cost comparison has a significant impact on the
total raw material cost of the finished products.
In this paper, the author gave an idea regarding risk identification for different processes using a fuzzy
approach which can be used for cost minimization in industry, and imaging process can help a lot in future
improvement (Rabbi 2018). Saeheaw et al. (2009) emphasized the use of Arena simulation software in a
hard disk drive production process in which average time and waiting time has decreased by a great amount.
Since the RMG industry has no automotive and manual handling is mandatory here. Junga et al. (2022)
presented a method for simulating a manufacturing line that uses data from real-time power monitoring,
specifically the individual task periods of the workers who make clothes. Using ICT-based power
monitoring devices, power consumption data for sewing machines used by workers are gathered. The data
is then sent over a wireless network to a cloud server where they are analyzed by an approximation
algorithm to determine the precise job time. An ICT-based PMS was developed and deployed to collect the
power profile data generated by the sewing machines on a garment production line, and an individual
worker’s task time was extracted by processing the collected power monitoring data through a pattern
analysis algorithm. Another study found by Unal et al. (2009), proposed a heuristic algorithm for line
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balancing and to simulate the algorithm's performance under various line configurations. Gurkan (2005)
interpreted how to provide weaving mills with ideas for organizing themselves more effectively and
estimating when their orders will be delivered using simulation techniques.
Ali et al. (2005) analyzed the performance of a combination of product mix and production volume
under different scenarios using reconfigurable assembly system modeling through the Arena simulation
software. Cycle time is an important factor for line balancing and Kibira et al. (2002) optimized the different
task issues such as line balancing, cycle time reduction, and material handling work using a discrete event
simulation model at which the effort and level of task during the simulation also pointed out. Moreover, a
relevant production work was presented in which Patel (2002) used a discrete event simulation model to
analyze the issues to ensure the development of efficient and effective processes that secures the system
throughput. Roy et al. (2021) interpreted face recognition during covid situation which is valuable for
worker health analysis during covid period. Potoradi et al. (2002) maximized the demand fulfillment in
which the simulation engine is used to schedule generation subject to system requirements and to control
the machine execution time. In this digital age, the industry requires a modern approach to visualize capacity
study with line feeding techniques for which Kamal et al. (2019) implemented an android system in
warehouses of the production line which can be the future study of this paper to make the model more
advanced. Ergonomic factors will be considered in the future research of this case study because the
ergonomics factor of an operator can contribute a lot to make more line production (Pervez et al. 2022).
The most ancient but remarkable specialist named Balci (1989) directs the simulation experts through the
life cycle's 10 procedures, 10 phases, and 13 stages of credibility assessment. The guidelines help simulation
practitioners with issue formulation, solution technique investigation, a system under study investigation,
simulation model formulation, representation, and programming, design of experiments, experimentation,
and model redefinition. Parvez et al. (2017) balance the line for the garments industry using the work
sharing method. They use a conventional layout system but not any simulation procedure.
The solution approach began by identifying the critical process of the production process and outlining
the parameters of line balancing. The disadvantages of conventional line balancing techniques are then
covered, along with the benefits of employing simulation software instead. Then, AnyLogic simulation
software is presented as a production line modeling and simulation tool. The case study is centered on a
fictitious T-shirt manufacturer. Many workstations, such as cutting, sewing, and packing stations, make up
the production line. To ensure that each workstation runs at its optimal efficiency, the production process
must be optimized. This study will examine several scenarios and methods for balancing the line, such as
changing the number of employees, workstations, and output rate. The simulation model is created using
AnyLogic simulation software, a powerful tool for modeling and assessing complicated systems. Users of
AnyLogic can model and simulate a variety of scenarios, from transportation networks to manufacturing
processes, using the software's user-friendly interface. We can pinpoint possible bottlenecks and streamline
the production process to boost output and cut costs by simulating various situations. A thorough report
containing visualizations of the production line, throughput, and efficiency will be the project's final
deliverable. Based on the results of the simulation, the report will also offer suggestions for enhancing line
balancing in the ready-to-wear business.
The report then goes on to detail the approach taken to increase the case company's production
efficiency. The bottleneck processes were initially determined by the authors' analysis of the current
production line. Afterwards, they modeled the production line and tested several line balancing situations
using the AnyLogic simulation software. The production line was optimized using the simulation data, and
worker and machine downtime was decreased. The results of the study show that the use of AnyLogic
simulation software can significantly improve the production efficiency of ready-made garment industries.
Overall, this project aims to demonstrate the benefits of using simulation software for line balancing in the
manufacturing industry. By optimizing production processes, companies can improve efficiency, reduce
costs, and ultimately provide better quality products to their customers.
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2 PROBLEM STATEMENT
The production line RMG industries are subject to change frequently within a short period of time. Changes
in production layout, adding or removing machines, new operators assigning are common scenarios in
RMG production lines. There are many reasons that these scenarios cannot be standardized such as
uncertain demand surge or recede due to the seasonal effect, changes in product style, new buyers on board,
etc. Since the buyer place orders of different styles of product at different industries based on the company’s
floor capacity, the production authority often faces challenges to meet this aggregate demand within a
limited amount of time to get the buyer’s order. However, the management must fulfill the production target
and meet the buyer’s and market needs. Of course, adding additional resources can ease the task, but the
management also considers the subsequent impact and cost effectiveness. At the same time managers
should have maintain line efficiency since there is a cost factor for every change in the production line. So,
the managers must come up with a responsive plan to fulfill the order and to maintain line efficiency through
appropriate changes such as allocation of machines, operators, working hours, etc. To do so, managers often
face challenges since they have a very limited idea of balancing a production line in a new set-up, especially
for a new style of product when there is no historical data. Moreover, the time constraints make the situation
more critical. In such a scenario, usually, the management relies on previous experience and applies the
trial-error approach to adjust the production line and achieve the desired efficiency level.
Obviously, this approach is very subjective, requires high level experience, and time-consuming
resulting in an unnecessary waste of time and resources. But with recent advancement of technology and
computation power, simulation can play a critical role in improving the situation. The application of
computer simulation enables us to perform experiments, adjust resources, understand its impacts, and make
a comprehensive plan. All of these can be done in digital platform without any allocation of physical
resources and waste of time. Thus, the simulation approach can help the managers to experiment with all
the scenarios, making a comprehensive plan ached of time and later implement them with confidence in the
physical production line. Hence, we demonstrate the simulation-based approach, where the managers can
experiment and take the effective decision before implementing in actual production environment. Thus, it
helps to make informed decisions and handle the challenges in production line settings. In this case study,
we used the Any Logic simulation software to experiment with five different scenarios.
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production process is shown in Figure 1. In this study, the Triangular distribution is used to model the
operation time at each workstation of the production line. The triangular distribution consists of the three
parameters a, b, and c for minimum, maximum, and mode values, respectively.
This strategy was chosen to take into consideration the fluctuating capacity of garment operators, which
varies from the beginning of production through the learning curve. Usually, the operators can complete an
operation within a certain average time. However, in some cases it may take longer time than usual,
especially in the event of some random occurrence such as part adjusting, machine malfunctioning, absence
of helping hand, or others. On the other hand, sometimes operators can complete their tasks in the minimum
possible time in favorable working conditions. Hence, the assumption of triangular distribution is
appropriate in this scenario. In particular, the operators' most frequent workload has been represented by
the mode value of the triangular distribution, while the performance range of variability has been captured
by the minimum and maximum values. Utilizing the triangular distribution in this situation offers a flexible
and efficient way to simulate the manufacturing process and account for the operators' fluctuating
capability. Here, Table 1 shows the standard capacity of different process operators with the triangular
distribution.
S/L 1 2 3 4 5 6 7 8 9 10 11 12 13
Capacity
300 120 180 250 120 130 90 120 300 130 350 300 110
Pcs/Hr.
Min 3 2 2 2 1 2 1 2 3 1 4 2 2
Max 6 3 5 5 3 4 4 3 6 4 7 3 3
Mode 5 2 3 4 2 2 2 2 5 2 6 5 2
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process carried out by single operator) for 1600 pcs output, but it took a significant amount of time more
than 20 hrs. with several bottlenecks in the process.
Figure 2: AnyLogic simulation model for the process flow of the production line.
Due to the shortage of 1 operator the output of the other workstations has been decreased, which creates a
bottleneck in the process. From this experiment, we can see that reducing one operator from the line makes
the whole system become infeasible because in that case more operating hours are needed (also, other
operators become overburdened) due to the shortage of one operator who would help them in several ways
during production say a little relaxation time when working) for the desired output and the efficiency is
significantly lower. This still results in underutilization of operators, which means the line is still
unbalanced, which can be observed in Figure 3-b. Hence the operator utilization problem has not yet been
solved for the desired line output with efficiency.
Scenario 5. To tackle the previously mentioned issue in Scenario 4, the author conducts a thorough
examination of the production line, specifically focusing on various workstations. The findings revealed
that by merging two processes side by side and assigning a single operator (in the other two processes
named sleeve tack and sleeve soap tack rather than it was Sleeve tack and Neck tape seam in Scenario 4 to
handle both, the desired output can be achieved with a reduced workforce of only 10 operators. This
innovative arrangement not only optimizes operator utilization but also enhances efficiency, as illustrated
in Figure 3-c. The implementation of this streamlined setup allows for seamless coordination between the
two processes, eliminating any potential bottlenecks and ensuring a smooth workflow.
By consolidating tasks and empowering operators to handle multiple responsibilities, the production
line operates with greater effectiveness, leading to improved productivity and resource allocation. This
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approach effectively tackles the challenges presented in Scenario 4 from Figure 3-b while offering a
practical solution that optimizes both manpower and output quality.
(a) (b)
120% 120%
100% 100%
80% 80%
60% 60%
40% 40%
20% 20%
0% 0%
(c)
120%
100%
80%
60%
40%
20%
0%
Operator Utilization
Figure 3: Utilization of Operators. (a) Scenarios 1 and 2, (b) Scenarios 3 and 4, (c) Scenario 5.
where G denotes total produced garments and T denotes total hours worked, the SMV (standard minutes
value, SMV = Basic Time + Allowances) is calculated using time study and motion study of the operators.
So, from the above discussed five scenarios, the best scenario of this case study is the fifth scenario for the
peak season with 1600 pcs output per day. Table 2 shows all the scenarios with different outcomes:
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Note that we have considered different operating minutes because during the off-season the line must
run on a standard 8-hr basis to maintain efficiency as demand is comparatively less during this time.
According to expert surveys and based on historical data, working overtime provides additional rewards
that significantly increase employee motivation. Additionally, the company gains from the reduced operator
presence because the fixed expenses are reduced. Therefore, it is advised to run the line with an optimal
amount of overtime, especially during the peak season. Thus, the industries avoid additional payments to
the extra operator throughout the year. Figure 4-a shows the efficiency of five different scenarios discussed
above based on the requirements. In addition, we demonstrate the cost incurred for each scenario. The total
cost depends on the operator’s standard (regular hour) salary, overtime cost, and penalty cost as shown in
Equation (2).
Y = B × E + (M × O) + P (2)
where B is the Basic salary, E represents the number of operators in the production line, M indicates
the overtime salary rate (Usually double of basic), O denotes the overtime hours, and P defines the penalty
cost for losing the target amount. Usually, the overtime salary is double the regular hour salary. The penalty
cost is directly related to the daily production target. Any amount below the production target is considered
as a penalty and thus related to the penalty cost. In this case study, such penalty cost is added for Scenario
1 and Scenario 3 resulting in the highest cost as is shown in Figure 4-b.
(a) (b)
20000
100.00% 18000
90.00% 16000
80.00% 14000
70.00%
Cost-Bdt
12000
Efficiency
60.00% 10000
50.00% 8000
40.00%
6000
30.00%
20.00% 4000
10.00% 2000
0.00% 0
1 2 3 4 5 1 2 3 4 5
Scenarios Scenarios
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labor requirements planning, and process improvement. Usually, process managers rely on their
experiences and/or traditional approaches for production planning, which sometimes lack proper
justification and validation. Whereas the simulation approach provides an informed decision by running the
production line in a digital platform and generates reliable decision-making outcomes. Regarding the
assessment of the behavior of the line and line balancing, the proposed approach can readily be used. In
this way, any unexpected situations can be prevented if a manager uses simulation model-based analysis.
In today’s competitive era, industries must respond rapidly to sustain and capture the market. In such cases,
it is indispensable to know about the current situation of the system to process the orders timely since it
involves high costs and Changeover time. For this reason, it is possible to forecast short-term and long-
term effects and boost productivity by creating a simulation model which is unparallel to a real-world
system.
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AUTHOR BIOGRAPHIES
S M ATIKUR RAHMAN is a Research Assistant in the Department of Industrial, Manufacturing and Systems Engineering
(IMSE) at the University of Texas at El Paso (UTEP). Currently, he is doing his M.S. degree in Industrial Engineering at UTEP.
He has completed his [Link]. degree in Industrial and Production Engineering. Mr. Atikur is working in the field of Simulation, Deep
Learning, and Smart Manufacturing Systems for Industrial Applications. Previously, he had Job experience in the field of Sourcing
& Procurement, Production, and Supply chain in different companies in Bangladesh for more than seven years. His email is
[Link].09@[Link] .
MD FASHIAR RAHMAN is an Assistant Professor of the Industrial, Manufacturing and Systems Engineering (IMSE)
Department at The University of Texas at El Paso. He holds a Ph.D. degree in Computational Science Program. He has years of
research experience in different projects in the field of image data mining, machine learning, deep learning, and computer
simulation for industrial and healthcare applications. In addition, Dr. Rahman has taught various engineering courses in industrial
and manufacturing engineering. His research area covers advanced quality technology, AI application in smart manufacturing,
health care applications, computational intelligence/data analytics, and decision support systems. His email address is
mrahman13@[Link] and the website is [Link] .
TAMANNA KAMAL is a Teaching Assistant in the Department of ISE at NC State University. Currently, she is doing her PhD
at NC state university and she had completed her [Link]. degree in Industrial and Production Engineering. She had served as an
Assistant professor at Khulna University of Engineering & Technology for more than five years. Moreover, she is working in the
field of Operations Research, Simulation, and Stochastic decision-making in the healthcare sector for Industrial Applications. Her
email address is tkamal1311@[Link] .
TZU-LIANG (BILL TSENG) is a Professor and Chair of the Department of Industrial, Manufacturing and Systems Engineering
at the UTEP. He is also a Director of the Research Institute for Manufacturing & Engineering Systems (RIMES), the host institute
of the Texas Manufacturing Assistance Center (TMAC) at UTEP. He received his two MSIE degrees (MFG & DS/OR) from the
University of Wisconsin at Madison and his Ph.D. in Industrial Engineering from the University of Iowa. Dr. Tseng’s research area
covers computational intelligence, data analytics, advanced quality engineering technology, and medical image processing. Over
the years, he has served as principal investigator sponsored by NSF, NIST, USDT, DoEd, KSEF, and industries like LMCO, GM,
and Tyco Inc. He is currently serving as an editor of the Journal of Computer Standards & Interfaces (CSI) and editor board of the
International Journal of Data Mining, Modeling, and Management (JDMMM). He is currently a Senior Member of the Institute of
Industrial Engineers and the former Chair of the Manufacturing Division of the American Society of Engineering Education
(ASEE). His email address is btseng@[Link] and the website is [Link]
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