A new line balancing algorithm for manufacturing cell transformation in apparel industry

Apparel manufacturing is a traditional industry with global competition. Thus any apparel manufacturer realizes the importance of improved production systems tries the best to finish the assembly work soon to increase on-time delivery and to increase machine/labour utilization to reduce production cost. Assembly line balancing is therefore a critical issue for the efficiency and competitiveness. In this study, six different line balancing algorithms are applied in shirt production band of a suit manufacturer which involves great number of operations. For this purpose, standard unit times of operations are determined by time study and statistical validations. Furthermore in order to add delay allowances to calculations, work sampling study is performed. Recent algorithms are examined by considering request of manager and a new algorithm which expresses the garment manufacturing process better is created. Thus, by comparing new algorithm with recent ones, other issues except utilization such as quality, Work flow direction and skills of operators are emphasized.