Performance optimization of pillow sheet set sewing assembly line by SAM analysis and lean manufacturing techniques of method study & work measurement

Abstract

This research was conducted to enhance the productivity of the targeted sewing line at the ABC textile company. The existing SAMs, the capacity of the sewing line for various operations, and several required machines were collected. Moreover, the obtained figures were observed and analyzed by using time study and motion study, and certain improvements were made at the sewing line. Results indicated that SAMs for operations A and B were minimized by -13.64% and -14.54% respectively; whereas, SAM for operation C was increased by 16.67%. Machine requirement for operation C was increased by 100%; moreover, the capacity for operations A, B, and C was increased by 12%, 12.69%, and 40% respectively. When it is to production activities, the little improvements play a significant role in boosting the productivity of the production system. Optimal allocation of human resources, machines, and time are the benefits of line balancing. This can be made possible with the application of the line-balancing framework. With every passing day, the nature and type of article vary at the sewing line thus it is highly needed for the company to get the model developed for an automated line balancing application. Moreover, this work can be extended by the development of a line-balancing framework considering the nature of production.

Keywords

• assembly line balancing
• performance
• lean manufacturing
• work measurement
• textile