Production Efficiency Efforts through Increasing Line Balancing Rate on Style S2xxxY

Abstract

In the garment industry, production efficiency often faces challenges due to imbalanced workloads across workstations, leading to bottlenecks and reduced productivity. This study aims to improve production efficiency by optimizing the line balancing ratio on the S2***Y trouser model in Hanger Line 1. The research methods included direct observation, cycle time data collection, fishbone analysis to identify imbalance factors, and the application of the ECRS (Eliminate, Combine, Rearrange, Simplify) method for process improvement. The fishbone analysis revealed several key issues: in the "man" factor, high cycle times were observed due to operators’ lack of process mastery; in the "method" factor, improper handling techniques increased the risk of product rejection; in the "machine" factor, the lack of early preparation for automatic bartack machines led to delays and downtime; and in the "material" factor, the use of bright, smooth, and slippery fabrics made handling difficult and highly susceptible to visible oil stains. By applying ECRS and modifying certain processes—such as replacing manual marking with template-based marking—the study achieved a 6% increase in production efficiency and a significant improvement in the Line Balancing Rate (LBR) from 53.10% to 82.40%, marking a 29.30% increase. These findings emphasize the crucial role of line balancing in enhancing output and overall production efficiency.