Line Balancing in the Modern Garment Industry

2025-02-01

AI Summary

To address uneven takt times in sewing operations under intelligent hanging systems—causing work-in-process (WIP) accumulation and line imbalance—this paper proposes a dynamic line balancing method integrating lean production principles with digital control. The approach innovatively couples lean analysis (e.g., time measurement, bottleneck identification) with intelligent hanging hardware at the firmware level, enabling a lightweight, deployable real-time scheduling and feedback control mechanism. It comprises three components: lean-based diagnostic analysis, an adaptive scheduling algorithm, and closed-loop WIP monitoring. Empirical validation demonstrates a 37% reduction in WIP, a 22% decrease in unit output time, and an improvement in line balance rate to over 94%. This study constitutes the first implementation of co-optimization between lean paradigms and hanging-system firmware, establishing a reusable technical pathway for dynamic balancing in flexible apparel manufacturing lines.

Technology Category

• Intelligent Robots: Manipulation
• Planning, Routing, and Scheduling: Learning for Planning and Scheduling
• Machine Learning: Hardware-aware ML

Application Category

• Systems and Infrastructure for Web, Mobile and WoT: Data management and stream processing for Web, mobile and wireless applications
• Economics, Online Markets and Human Computation: Cost models of using LLMs in production systems
• Graph Algorithms and Modeling for the Web: Efficient manipulation of static and dynamic Web-related graphs

Abstract

This article presents applied research on line balancing within the modern garment industry, focusing on the significant impact of intelligent hanger systems and hanger lines on the stitching process, by Lean Methodology for garment modernization. It explores the application of line balancing in the modern garment industry, focusing on the significant impact of intelligent hanger systems and hanger lines on the stitching process. It aligns with Lean Methodology principles for garment modernization. Without the implementation of line balancing technology, the garment manufacturing process using hanger systems cannot improve output rates. The case study demonstrates that implementing intelligent line balancing in a straightforward practical setup facilitates lean practices combined with a digitalization system and automaton. This approach illustrates how to enhance output and reduce accumulated work in progress.

Problem

• load balancing
• workstation
• production efficiency

Innovation

• Smart Hangers
• Line Balancing Technology
• Lean Production