Research On Shirt Production Line Optimization Based On Constraint Theory

As a traditional labor-intensive industry,garment manufacturing industry is backward in production level and management mode,and its production capacity and quick response ability cannot meet the current market demand for multi-batch and small-batch products.Therefore,clothing manufacturers need to constantly evolve and improve their production management mode to meet the challenges of the current market.At present,the mode of clothing production management mostly relies on experience,and the mode and level of production management are too subjective and unstable.Therefore,a set of standardized production management mode is urgently needed in the clothing manufacturing industry.This topic to a traditional shirt production line as the research object,through the assembly line production problem analysis,using scientific method to establish the garment production bottleneck comprehensive judgment model,realized the accurate screening of garment production bottlenecks,and provides a bottleneck of partial improvement method and assembly line balance model in order to realize the assembly line and minimum bottleneck,weaken the bottleneck location restrictions on production system output.Firstly,through the field survey of shirt workshop,literature research and interviews with front-line managers,the paper summarized and analyzed the bottleneck identification indicators and methods of various industries.According to the opinions of the front-line managers and the actual situation of shirt production,five bottleneck indexes of clothing production were determined,including capacity load of the station,time utilization rate of the station,timeout coefficient,work-in-process backlog quantity and repair rate.The weight was determined by analytic hierarchy process(ahp)and a comprehensive bottleneck model was established by TOPSIS method.Secondly,in combination with the constraint theory,the balance model of shirt assembly line is established with the goal of uniform working hours,minimum number of working stations and minimum number of beats for each station,which weakens the constraint of bottleneck work stations on the production system,and the genetic algorithm is designed to realize the solution of the model.Finally,combining the characteristics of shirt production and constraint theory,the bottleneck management methods,such as local improvement of bottleneck,optimization of pipeline balance and optimization of bottleneck circulation,are proposed.The simulation results show that the output of the target production line has been greatly improved after bottleneck optimization and process rearrangement.The daily output of the production line has increased from 771 pieces/day to 856 pieces/day with an increase of 11%.Establishment efficiency increased from 81.03% to 91.38%;The average time utilization increased from 81.05% to 87.78%,and the optimization effect of production line was significant,which verified the effectiveness of the bottleneck identification model and the multi-objective optimization model of pipeline proposed in this study.