Clothing Production Sewing Process Load Balance Research

Abstract: In the production of clothing, sewing process, is the main production link. This paper introduces the clothing line load balance theory and its important parameters, discusses the process of load balance method and steps, and the combination of a skirt suit process layout example, through reasonable arrangement of lines on the manpower and the number of devices, in order to improve the clothing production efficiency. Introduces the sewing process layout of apparel production line and the process load balance theory, discusses the clothing line load balance of the basic method, and combined with the actual production process layout of jeans are analyzed.

Key words: Clothing production, sewing production line, process scheduling, load balancing

1. Questions:

In the garment processing and production experiments, we want to produce an enterprise to solve the problem of supply and demand of process and efficiency. According to the survey results, this problem is the key problem of small and medium enterprises management. Study according to the current clothing production from the expected products made from the whole process of actual, arrangement of teaching experiment, fulfil each process operating conditions and layout requirements, will effectively improve business processes. Clothing production efficiency mainly by the sewing process to determine the efficiency of sewing workshop, production line balance production of clothing is the key research content. At present company of our country clothing, sewing process of preparation and equipment used mainly by experience, intuition, estimation, lack of scientific basis, often resulting in sewing process load imbalance, labor and production equipment are not fully utilized, often delay, error phenomenon. Study on the method of load balance in sewing process, improve the efficiency of the assembly line, can reduce the waste of resources, improve the management level and economic benefits, enhance the enterprise competitive ability. Combining many years of apparel production management experience, summarizes some methods and everybody to be discussed jointly.

2. Process analysis

Garment enterprises more popular is the hanger production line, garment sewing process layout of the load balance is a clothing production base in the process of work. Garment sewing process layout load equilibrium theory for the garment sewing process layout of the workshop provided theoretical basis, can save manpower, improve product quality and production efficiency as the final purpose. Through the process of reasonable decomposition and composition and process of the standard processing time, reasonable arrangements for each procedure of manpower and equipment, through the standard theory and mathematical model to improve the efficiency of the process layout, so that enterprises can adapt to the fast delivery of market demand for clothing assembly line arrangement.

Hypothesis of sewing process line a total of K process, process I one-piece standard operation time is Ti ( I = 1, 2, 3 ... ... K ), a standard total processing time for the T, production lines of beats for P0, Ti and P0 in the production of process has the following 3 kinds of circumstances:

(1)Ti > P0, generally do not allow this to happen, this means that the I process is long-term excess load runs, the procedure is to be expected, the process is usually called " bottleneck".

(2) Ti = P0, this is the ideal state, is the strong beats homework.

(3) Ti < P0, said the process at every time some free production time.

Industrial garment production is a clothing production is divided into several processes, by different personnel cooperate to complete, each repeated operation their share in the work. In this way the advantages, production personnel engaged in only a single operation, production skills can be improved rapidly in a short time, so the production efficiency is high. At the same time, even if the operator level level, product quality did not differ too much, and because each process to specialized operation, easy to introduce special machine or automaton. But this mode of production has its inevitable shortcomings, because the production staff only operate the specific processes, so impossible to master other processes; this producer between each have great relevance degree, if the production line was absent, a part of the process will stagnate, which affects the overall production. In other words, this mode of production is smooth or not is how to achieve synchronization of the division of labor.

(1)Sewing assembly line balancing requirements:

(2)According to the process of order, reasonable to distribute to every workstation.

(3)For each workstation operating time to average tempo, and the lines on the workstation at.

(4)The idle time of each workstation to less, and allow the station between uniform load, so as to ensure the line loss rate of time minimum.

The assembly line equipment used minimize, reduce the amount of more than one machine.Procedure synchronization is the necessary conditions for organizing production lines, but also to improve the load and the labor productivity, shorten the period of production important method. On garment sewing, a reasonable sewing process portfolio presentation scheme not only can achieve uniform load operation, can effectively reduce the consumption of all kinds of resources in enterprises. On the lines of" rhythm" and" balanced" smooth clothing lines just like a piece of beautiful music, which one of the elements is" the beat movement". Clothing line" beats" refers to the production line of products in the process of each movement a desired time interval. It determines the production capacity, production speed and efficiency. In the sewing process design, if given a process essential daily output, first consider the process. While usually put a process in the production rhythm of the slowest link called" bottleneck". Process bottleneck in the only limits the flow speed of the product, but also affected other link production ability. More broadly, the so-called load balance refers to the whole process of the outputs of the various factors restricting the bottleneck to solve problems.

The actual production of the real decision production line speed is the bottleneck of the beat, average tempo as the process layout with reference value, bottleneck beat is maximum processing time and more than average tempo beat, i.e. the time maximum load and difficult to process improvement process rhythm, it need the most attention production organizer. For example, in some cases, may use the shortage of manpower, raw materials can not be timely, a part of equipment failure, information flow block, there may be a bottleneck. As the" bottleneck" of the literal meaning, a bottle mouth size determines the liquid to flow out from the speed, production process bottleneck is restricting whole process output speed. Bottleneck may also" drift", depending on the specific time period production of the products or the use of manpower and equipment. Therefore, in the process design and the future daily production operation need to cause enough attention. In the actual production, the real decision production line speed is the bottleneck, the beat is mainly composed of workers skilled operation to ensure. The average of all working time line programming efficiency reflects the balance of the process arrangement, general requirements for garment enterprises operation efficiency reach above 85%. This requires the production process balance. Garment sewing was subdivided after multiple process flow of continuous operation, after this operation after fractionize, each process operating time in theory and reality cannot be identical, this certanly will exist between process of beat is not consistent, occurrence bottleneck phenomenon.

Once the bottleneck phenomenon, will have a" free time". Idle time is the working time without performing effective work time, can refer to the equipment or the people of the time. When a process in each process of the beats are not consistent, the bottleneck of other processes can produce idle time. Idle in addition to cause unnecessary loss, but also caused a large number of process lag deposit is deposit goods, but also caused serious production suspension. In order to solve the above problem must the process operating time average, while the operation standardized, so that the production line can be smoothly activities.

3. Process balance

" Production line balance" is the production of the entire process is averaged, adjusting the operation load, so that the operation time as near as possible. To achieve a balance of the three elements to achieve balance consists of three elements: cycle time; operation order; standard reserves. Cycle time or per unit time, refers to the sewing clothing some parts of the time required, it can be accurate to seconds. This is determined by the amount of production, demand and machine to actuate a time to decide. Cycle time is a production number divided by the duration of labor results. Although the cycle time was identified, but because the producer's proficiency in different there will be individual differences. Because live by the people to do, if for some individual differences or because the body caused by uneven, will take a engaged in the job of the people work offset, this is like relay race in passing the baton. People often say:" time is the operation of shadow." Most of the" slow" is the result of operation and program wrong generated. How to correct, will see site supervision personnel ability. Treatment of lower level English new workers, must be taught, this will increase the personnel to supervise staff within the trust. At the same time, but also can promote the staff and workers of the linkages between, can create the conditions of "mutual aid".

The best process load balance scheme:

(1)Cyclophos phamide to beat as a prerequisite to personnel, should be at least as the goal, to determine the work to a minimum number of ( best value ).

(2)To work a number of prerequisites, should be given the largest staff production as the goal, and to seek the minimum cycle time ( or time ). Whatever the conditions, the process of my spare time should be the minimum.

(3)And by the permit within the scope of the beat and work number, in order to maximize the economic benefits as the goal, to achieve maximum efficiency of compiling, which determines the actual production rhythm and the work number.

(4)Based on a predetermined set of system efficiency as a prerequisite, should take the beats and the preparation efficiency to determine the preparation time of the upper and lower, to determine a number and the actual operation personnel. Beat boundaries is process combination calculation for limited time range, upper and lower division beat beat. Considering the business to process layout efficiency, generally take boundaries line.7% to 10% .

Preparation time limit = production time of P0 / preparation efficiency ETA

Compile time minimum limit = 2 × P0—compile time limit

Study on load balance in production line procedure, according to different load balancing scheme factors to be taken into account are product types, quantity, process order and the operation time, the standard time, working hours, workers and the number of expected yield. Ready-to-wear process analysis, the simplified procedure of standard processing time ( or output), clear processing sequence and method. Standard processing time is a general skill level of operators operating time, some operators processing time than standard processing time is short, some long. Check the working procedure is simplified, the number in decimal rounding or equipment waste phenomenon or away from the average beat phenomenon, analyze and determine whether with other procedures are combined, such as the production process to allow, can be combined, calculates the combined standard processing time.

Operation sequence, as the name suggests is that operating personnel in the delivery of garment parts, machine" on the job"," Stop working" in the process, according to the time order of the processing sequence. It must be stressed, it is not necessarily the product along the line moving sequence. Standard reserves, refers to the job, stay on the station 's necessary number of pieces of processing. The general standard is attached to each machine garment processing components, namely to enough use, stations do not have inventory. To achieve balance, we must first calculate lines every procedure of the average processing time. For example, production jacket total processing time is 4697 seconds, the average position of the processing time of 151 seconds. But because the procedure is relatively complete, being split into the standard average processing time, so only around the standard average processing time on floating. At the same time, according to the worker technical arrangement adjustment process, mainly consider the components for assembly line workers technology expertise and comprehensive quality. As some of the workers for the previous process can not be arranged in the following process; for the comprehensive technical workers, should be arranged in a greater technical difficulty processing time and multiple working procedure. Prior to consider employee absenteeism and sick and situation, timely adjust, otherwise there will be a pipeline stall or blocking phenomenon, affecting the production efficiency. When the pipeline operation required in each station maintains 3 rack reserves, namely the reserve 3 products pieces or semi-finished products, reserves too much or too little, come true hard lines smooth and fast. There must be clear, although the process of different duration, but decided to production line operation cycle of the procedure for only one time, namely, the longest time, that is to say the long process time is equal to the beat.

Reference

[1] Yang Yixiong, clothing production management ( Second Edition ) [ M]. Shanghai: Shanghai science and Technology Press, 2001

[2] Wan Zhiqin, clothing production management [M ]. Beijing: China Textile Press, 1992.

[3] Li Yinzhi, sewing production line balance method [J ]. Journal of textile research, 2002, ( 3)

[4] Li Kejing, Cui Shizhong, the modular design and manufacture of apparel development [J ]; Textile journal, 2006(1)

[5] for book Fang, Zhang Xiaochuan, Liao Sanli, based on the load balance of production rhythm design [J ]; Journal of Wuhan University of Technology ( Science and Engineering), 2007 (1)