Optimizing Production System Flow and Simulation for Production Effectiveness:A Case of Lucy Garment Industry
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Date
2023-10
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Addis Ababa University
Abstract
Textile and Apparel industry is one of the priority sectors of Ethiopian manufacturing sector having a substantial contribution in GDP of the economy. Most of the apparel factories of Ethiopia are export oriented earning highly demanded foreign exchange. However, the productivity of Ethiopian garment industries is currently low, failing to meet the existing demand and supply of their products. This study focuses on the case of Lucy Garment Industry, which produces shirts and faces a significant discrepancy between expected and actual outputs. Despite high market demand, the industry struggles to achieve its target output. The objective of this research is to identify and address the factors that contribute to low productivity in the garment industry. The identified factors include unwanted movement, unbalanced operation processes, ineffective time management, low labor motivation, product loss and low output per labor. The research methodology involves the use of Arena simulation software to analyze data and propose alternatives. Additionally, Flexsim2021 employed to optimize the production arrangement flow and reduce the distance movement of workers. Excel 2010 and QM for Windows V5 utilized to implement the proposed results and present data through graphs and charts. The findings of this study indicate that by addressing the identified factors, overall productivity in Lucy Garment Industry can improved. The proposed improvements result in an increase in daily output to 474 pieces, with an efficiency rate of 79%. Moreover, the output per labor per day enhanced to 15 pieces, while unwanted movement reduced to 67.6m. The study also reveals reductions in loss (21,600 ETB per year) and ineffective time (2,175 minutes per year). Additionally, labor requirements reduced by two, and the number of IRN and SNL machines also decreased. In conclusion, this research highlights the importance of management's role in facilitating productivity improvements in the garment industry. By implementing the proposed interventions and creating favorable working conditions, companies can enhance productivity, meet customer demands, and contribute to the economic growth of the country.