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Optimizing Sewing Line Balancing in Apparel Manufacturing through Digitalization

Bülent Koç

Bülent Koç

Istanbul Technical University, Faculty of Textile Technologies and Design, Textile Engineering DepartmentIstanbul, Türkiye
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Koç, Bülent
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Selin Hanife Eryürük

Selin Hanife Eryürük

Istanbul Technical University, Faculty of Textile Technologies and Design, Textile Engineering DepartmentIstanbul, Türkiye
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Eryürük, Selin Hanife
  
May 28, 2025
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Article Category: Research Article
Published Online: May 28, 2025
Page range: 10 - 26
DOI: https://doi.org/10.2478/ftee-2025-0002
Keywords
© 2025 Bülent Koç et al., published by Sciendo
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 3.0 License.

Fig. 1.

Process Monitoring Device (PMD)
Process Monitoring Device (PMD)

Fig. 2.

Dynamic Workflow Optimization Framework for PMD
Dynamic Workflow Optimization Framework for PMD

Fig. 3.

Overview of Digitalization in Garment Manufacturing
Overview of Digitalization in Garment Manufacturing

Fig. 4.

Image of the D6250 Ladies’ Trouser Model
Image of the D6250 Ladies’ Trouser Model

Fig. 5.

Sewing Process Workflow Chart for the D6250 Trousers
Sewing Process Workflow Chart for the D6250 Trousers

Fig. 6.

Software Algorithm Optimization Interface
Software Algorithm Optimization Interface

Fig. 7.

Operation Priority and Dependency Input Screen for Ranked Positional Weight (RPW) Calculation
Operation Priority and Dependency Input Screen for Ranked Positional Weight (RPW) Calculation

Fig. 8.

Calculation of the Ranked Positional Weight (RPW) Method for Optimizing Operation Assignments
Calculation of the Ranked Positional Weight (RPW) Method for Optimizing Operation Assignments

Fig. 9.

Screen Displaying Optimization Result Values
Screen Displaying Optimization Result Values

Fig. 10.

Access Interface for Line Optimization Results and Yamazumi Chart in the Digital Line Balancing Program
Access Interface for Line Optimization Results and Yamazumi Chart in the Digital Line Balancing Program

Fig. 11.

Total Durations of Operations Assigned to Workstations
Total Durations of Operations Assigned to Workstations

Fig. 12.

Current Sewing Line Layout for the D6250 Trouser Model
Current Sewing Line Layout for the D6250 Trouser Model

Capacity Algorithm Application Based on the Cycle Takt Time for the D6250 Trousers Model

Task Number Operation Machine SMV (min.) Performance % Actual SMV (min.) Takt Time (min.) Required Operator Assigned Operator Leap Operator Unassigned Time (min.)
1 Belt Ironing Ironing Board 0.296 63.00 0.470 0.626 0.751 0 0.751 405.43
2 Elastic Joining Elastic Feeding 0.206 75.00 0.273 0.626 0.436 0 0.436 235.50
3 Belt Elastic Marking Manual 0.264 80.00 0.330 0.626 0.527 0 0.527 284.66
4 Elastic Holding Flatlock 0.560 54.00 1.037 0.626 1.657 1 0.657 354.54
5 Belt Joining Lockstitch 0.294 77.00 0.382 0.626 0.610 0 0.610 329.52
6 Belt Closing Flatlock 0.496 50.00 1.002 0.626 1.601 1 0.601 324.35
7 Cuff Ribbing Attachment Lockstitch 0.698 75.00 0.929 0.626 1.484 1 0.484 261.37
8 Front Panel Attachment Lockstitch 0.480 70.00 0.690 0.626 1.102 1 0.102 55.21
9 Front Seam Joining (x2) Lockstitch 0.599 78.00 0.768 0.626 1.227 1 0.227 122.49
10 Back Panel Joining Lockstitch 0.555 67.00 0.824 0.626 1.316 1 0.316 170.80
11 Inner Seam Joining Lockstitch 0.867 101.00 0.862 0.626 1.377 1 0.377 203.58
12 Belt Attachment Overlock 0.618 56.00 1.114 0.626 1.780 1 0.780 420.96
13 Belt Cuff Coverstitch 0.591 76.00 0.782 0.626 1.249 1 0.249 134.57
14 Hem Bar Tack (x2) Bar Tack 0.345 30.00 1.142 0.626 1.824 1 0.824 445.11
15 Label Attachment Flatlock 0.315 63.00 0.500 0.626 0.799 0 0.799 431.31
16 Label Removal (x9) Manual 0.309 75.00 0.415 0.626 0.663 0 0.663 357.99
17 First Control Manual 0.505 78.00 0.650 0.626 1.038 1 0.038 20.70
18 Ironing Ironing Board 0.587 76.00 0.776 0.626 1.240 1 0.240 129.39
19 Final Control Manual 0.606 42.00 1.428 0.626 2.281 2 0.281 151.82

Task Times for Assigned Operators and Workstations

Task Station Number Operation Machine Operator Station Time (min)
1 15 Belt Ironing Ironing Board Ironing Board M.C. 405.43
2 16 Elastic Joining Elastic Feeding S.A. 235.5
3 17 Belt Elastic Marking Manual N.K 284.66
4 1 Elastic Holding Flatlock M.E 540
4 18 Elastic Holding Flatlock B.I 354.54
5 19 Belt Joining Lochstitch G.K 329.52
6 2 Belt Closing Flatlock S.Y 540
6 20 Belt Closing Flatlock H.S 324.35
7 3 Cuff Ribbing Attachment Lockstitch Z.K 540
7 16 Cuff Ribbing Attachment Lockstitch S.A. 261.37
8 4 Front Panel Attach+ Label Removal Lockstitch AY.P. 540
8 18 Front Panel Attach+ Label Removal Lockstitch B.I 55.21
9 5 Front Seam Joiningx2 Lockstitch SE.A. 540
9 18 Front Seam Joiningx2 Lockstitch B.I 122.49
10 6 Back Panel Joining Lockstitch M.G 540
10 19 Back Panel Joining Lockstitch G.K 170.8
11 7 Inner Seam Joining Lockstitch H.T 540
11 20 Inner Seam Joining Lockstitch H.S 203.58
12 8 Belt Attachment + Thread Cleaning Overlock S.H 540
12 21 Belt Attachment + Thread Cleaning Overlock MH.E. 420.96
13 9 Belt Cuff Coverstitch Coverstitch Y.T 540
13 22 Belt Cuff Coverstitch Coverstitch AY.E. 134.57
14 10 Hem Bartack x2 + Thread Cleaning Bartack ER.T 540
14 23 Hem Bartack x2 + Thread Cleaning Bartack AY.K 445.11
15 24 Decorative Label Attachment Flatlock EL.O. 431.31
16 25 Label Removal X9 + Turning and Stacking Manual SE.K. 357.99
17 11 First Control Manual SV.M. 540
17 25 First Control Manual SE.K. 20.7
18 12 Ironing Ironing Board UG.D. 540
18 25 Ironing Ironing Board SE.K. 129.39
19 13 Fınal Control Manual HU.Y. 540
19 14 Fınal Control Manual KA.A. 540
19 26 Fınal Control Manual ME.M 151.82

j_ftee-2025-0002_tab_006

Details Values
Start of Shift 08:00
Time at Measurement 12:00
Downtime 30 minutes
Production Quantity 250 pieces
Standard Minute Value (SMV) 0.5 min/pcs

Sewing Work Elements, Machine Types, and Standard Minute Values for the D6250 Trousers

Task Number Operation Machine SMV (min)
1 Belt Ironing Ironing Board 0.296
2 Elastic Joining Elastic Feeding 0.206
3 Belt Elastic Marking Manual 0.264
4 Elastic Holding Flatlock 0.560
5 Belt Joining Lockstitch 0.294
6 Belt Closing Flatlock 0.496
7 Cuff Ribbing Attachment Lockstitch 0.698
8 Front Panel Attachment Lockstitch 0.480
9 Front Seam Joining (x2) Lockstitch 0.599
10 Back Panel Joining Lockstitch 0.555
11 Inner Seam Joining Lockstitch 0.867
12 Belt Attachment + Thread Cleaning Overlock 0.618
13 Belt Cuff Coverstitch 0.591
14 Hem Bartack (x2) + Thread Cleaning Bartack 0.345
15 Label Attachment Flatlock 0.315
16 Label Removal (x9) + Turning & Stacking Manual 0.309
17 First Control Manual 0.505
18 Ironing Ironing Board 0.587
19 Quality Control Manual 0.606

Comparative Analysis of Key Production Metrics Before and After Optimization

Operational Metric Before Optimization After Optimization Difference Percentage Change
Daily Production Quantity 718 pieces 862 pieces +144 pieces +20.06%
Daily Working Time 540 minutes 540 minutes
Total Actual Standard Time 14.37 minutes 14.37 minutes
Line Efficiency 79.68% 88.31% +8.63% +10.83%
Number of Current Operators 24 employees 26 employees +2 people +8.33%
Labour Productivity 30 pieces 33 pieces +3 pieces +10%

j_ftee-2025-0002_tab_007

Calculations Formula Details
Production Time 250pcs × 0.5min/pcs 125 min
Time Difference 12:00 − 08:00 = 4hours 240 min
Actual Working Time 240min − 30min 210 min
Performance Calculation ((125 min)/(210 min)) ×100 59.5%

Capacity Calculations Based on Task Durations of Work Elements for the D6250 Trousers Model

Task Number Operation Machine SMV (min.) Hourly Amount Capacity (Employee/Machine) Working Hours
1 Belt Ironing Ironing Board 0.296 202.70 0.47 4.23
2 Elastic Joining Elastic Feeding 0.206 291.26 0.33 2.97
3 Belt Elastic Marking Manual 0.264 227.27 0.42 3.78
4 Elastic Holding Flatlock 0.560 107.14 0.89 8.01
5 Belt Joining Lockstitch 0.294 204.08 0.47 4.23
6 Belt Closing Flatlock 0.496 120.97 0.79 7.11
7 Cuff Ribbing Attachment Lockstitch 0.698 85.96 1.11 9.99
8 Front Panel Attachment Lockstitch 0.480 125.00 0.77 6.93
9 Front Seam Joining (x2) Lockstitch 0.599 100.17 0.96 8.64
10 Back Panel Joining Lockstitch 0.555 108.11 0.89 8.01
11 Inner Seam Joining Lockstitch 0.867 69.20 1.38 12.42
12 Belt Attachment + Thread Cleaning Overlock 0.618 97.09 0.99 8.91
13 Belt Cuff Coverstitch 0.591 101.52 0.94 8.46
14 Hem Bartack (x2) + Thread Cleaning Bartack 0.345 173.91 0.55 4.95
15 Label Attachment Flatlock 0.315 190.48 0.50 4.50
16 Label Removal (x9) + Turning & Stacking Manual 0.309 194.17 0.49 4.41
17 First Control Manual 0.505 118.81 0.81 7.29
18 Ironing Ironing Board 0.587 102.21 0.94 8.46
19 Quality Control Manual 0.606 99.01 0.97 8.73
Language:
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Publication timeframe:
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Journal Subjects:
Business and Economics, Business Management, Business Informatics, Process Management, Industrial Chemistry, Cellulose, Paper and Textiles, Polymer Science and Technology, Materials Sciences, Biomaterials and Natural Materials
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