Heliyon 10 (2024) e23585

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Heliyon
journal homepage: www.cell.com/heliyon

Productivity improvement through assembly line balancing by

using simulation modeling in case of Abay garment
industry Gondar
Melkamu Mengistnew Teshome a, Tamrat Yifter Meles b, *, Chao-Lung Yang a
a
Department of Industrial Management, National Taiwan University of Science and Technology, 10657, Taipei, Taiwan
b
Department of Industrial Engineering, University of Gondar, Institute of Technology, Gondar, Ethiopia

A R T I C L E I N F O A B S T R A C T

Keywords: This study aims to balance the garment line of the polo shirt operation by utilizing line balancing
Productivity techniques. These techniques are employed to enhance the efficiency and productivity of the
Line efficiency Abay garment industry. Observational methods and stopwatch timing were employed to collect
Line balancing
data on the processing times for each operation. Subsequently, the standard allowed minute was
Simulations modeling
Garment
determined based on work measurement principles. To assess statistical significance and identify
appropriate expressions for the existing simulation modeling, all collected data underwent sta­
tistical analysis using the Arena input analyzer. Moreover, Arena simulation software was
employed in this research to simulate and evaluate the effectiveness of both the current and
proposed polo shirt sewing line models. Building upon the existing model, alternative improved
models were proposed. The alternative models yielded significant improvements in multiple
performance metrics, including output, capacity utilization, waiting time in queues, and number
of products waiting. These improvements indicate an increase in productivity resulting from the
implementation of balanced production lines. The outcomes of the improved scenario included an
increase in output from 288 to 381, a rise in line efficiency from 39.06 % to 55.64 %, and an
enhancement in labor productivity from 54.25 % to 66 %. Additionally, the cost of labor was
reduced by 15.63 %, while revenue experienced a notable increase of 30 %.

1. Introduction

In today’s world, the manufacturing industry has a significant contribution to the growth of one country. Among the different
manufacturing sectors, one is garment manufacturing. The garment manufacturing industry is renowned for its labor-intensive nature
and has evolved into one of the world’s largest economies. It capitalizes on labor-intensive advantages, especially in regions facing
increasing urban unemployment rates [1]. Moreover, recent reports highlight the textile and apparel industries as some of the
fastest-growing sectors, providing employment to millions of individuals [2]. For countries like Ethiopia, with significant populations
and high unemployment rates, these industries hold even greater value.
The garment and textile industries in Ethiopia have a long history, dating back to around 1939, but only recently have they begun to
modernize. These industries are now a priority, significantly contributing to the country’s GDP. However, many garment factories in

* Corresponding author.
E-mail addresses: melkindustrial@gmail.com (M.M. Teshome), tamratyifter@gmail.com (T.Y. Meles), clyang@mail.ntust.edu.tw (C.-L. Yang).

https://doi.org/10.1016/j.heliyon.2023.e23585
Received 4 May 2023; Received in revised form 24 November 2023; Accepted 7 December 2023
Available online 21 December 2023
2405-8440/© 2023 Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
M.M. Teshome et al. Heliyon 10 (2024) e23585

Ethiopia still operate inefficiently [3]. Therefore, exploring ways to enhance efficiency in this sector has become a crucial focus for
researchers. This study aims to seize this opportunity by specifically focusing on improving the Ethiopian garment industry.
To increase the annual earnings potential in Ethiopia, the productivity of the garment sector is a significant factor. Increased
productivity is thought to boost profitability and workers’ ability to earn a living wage because it is frequently cited as a crucial
component of industrial performance [4]. The efficiency with which input resources are converted into value for customers is a critical
factor in assessing the productivity of a process. Manufacturers of physical products extensively adopt a variety of productivity
frameworks and metrics. Increasing productivity not only bolsters profit margins for enterprises but also curtails the production ex­
penses in the garment industry [5]. For augmenting productivity, a streamlined and balanced workflow is essential. Line balancing
plays a crucial role in this process by distributing the amount of work uniformly across all operations within a value stream, thus
averting inefficiencies such as bottlenecks and capacity problems [6].
According to the preliminary study, the case company, specializing in polo shirt production, is facing a line balancing challenge that
is leading to a significant discrepancy between the target and actual production output. The current assembly line is experiencing
imbalanced workloads among operators, which has resulted in bottlenecks, idle time, and excessive workloads. Consequently, the
company struggles to meet production targets, resulting in delivery delays and reduced profitability. Therefore, implementing a line
balancing strategy is imperative for the company.
Line balancing is a critical aspect of production processes in various industries, including manufacturing [7]. It involves the
optimization of task allocation and resources to ensure a smooth and efficient production process. Consequently, this study has chosen
to employ line balancing techniques, given their widespread use in addressing issues that arise in assembly line operations and in
minimizing disparities between workers and workloads to attain the necessary production rate [8].
Despite its importance, line balancing can be challenging to implement effectively. The primary problem is identifying and
addressing bottlenecks in the production process, which can lead to idle time, longer cycle times, and potential quality issues.
Additionally, different tasks require different skill levels, and worker fatigue and other factors can impact production efficiency.
Similarly, managers must make informed decisions about the pace at which operators work to maintain process continuity and
determine the appropriate number of operators for specific tasks, all while ensuring that efficiency gains remain at satisfactory levels.
To handle those difficulties, the researchers use a computer simulation tool, since the simulation is a valuable tool for garment
manufacturers in line balancing as it enables them to identify bottlenecks, analyze process efficiency, reduce downtime, optimize
worker utilization, and implement changes cost-effectively. Employing simulation in line balancing results in increased efficiency,
productivity, and profitability [9].
Equally, it is an important tool for line balancing because it allows manufacturers to evaluate different scenarios and strategies for
optimizing their production process without actually implementing them in real life [10]. By creating a virtual model of the production
line and running simulations, manufacturers can test different line balancing strategies without incurring the costs associated with
physical changes to the production line.
Hence, the main goal of this study is to enhance the production line for polo shirt manufacturing at Abay Garment Industry by
applying line balancing through simulation modeling. To achieve this, the study aims to address the following objectives:

1. Analyze the current production line to identify bottlenecks, areas of inefficiency, and opportunities for improvement.
2. Develop a line balancing plan to optimize the production line by eliminating bottlenecks, reducing idle time, and ensuring that each
worker is performing tasks that align with their skill level.
3. Determine the effectiveness of the line balancing plan by tracking key performance indicators, such as production output, waiting
time, costs, and profits. These indicators can be used to assess the success and impact of the proposed line balancing plan.

1.1. Literature review

1.1.1. Overview of the garment industry in Ethiopia

Ethiopia presents a promising landscape for the future of apparel manufacturing, considering its large youthful populace of 110
million, swift economic advancements with expected sustained annual GDP growth, competitive labor costs, and favorable trade
conditions [11]. Despite its potential, Ethiopia faces several challenges that impact commercial viability, environmental sustainability,
and ethical business practices. Critical materials such as cotton, fabrics, and accessories necessitate importation, and the country’s
import-export regulatory framework is complex and often results in protracted processes.
The Ethiopian government is working to increase income and attract foreign investment in the textile and garment sectors. It has
offered incentives including export benefits, access to low-cost land, reduced-interest loans, tax holidays, and exemptions on duties for
importing equipment. The establishment of entities such as Industrial Development corporations, tasked with the development of
modern industrial parks, has notably heightened the country’s attractiveness to foreign investors [12].
The garment manufacturing industry in Ethiopia, a priority for the government, faces challenges in productivity. These challenges
present a significant opportunity for research aimed at improving productivity, a crucial strategy for enhancing the industry’s per­
formance in the country [13].
Analyzing current manufacturing systems in the garment industry can be costly and, at times, unfeasible. The complexity is due in
part to the fast-paced and intricate nature of production where multiple processes occur simultaneously. The interactions and tran­
sition times between workers add to this complexity, making the examination of the system challenging [14].

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1.1.2. Productivity
Productivity, a fundamental concept in economic analysis, has a history spanning over two centuries and finds application in
various economic contexts at different levels of aggregation [15]. It measures the efficiency of transforming inputs into outputs, a
crucial idea in economic analysis, often evaluated based on the attainment of established goals related to input-output relationships
within industries [16]. Mathematically, this concept is encapsulated in Equation (1).
output
Productivity = (1)
input
Productivity is widely regarded as a pivotal factor governing economic production activities, often considered the most crucial one.
It serves as a key metric for evaluating the efficiency and effectiveness of service or manufacturing organizations in generating output
with the resources at their disposal. One effective approach to enhancing productivity is optimizing task scheduling, involving the
sequencing of tasks to minimize the time spent switching tools or work pieces between tasks. Logical and efficient task sequencing
minimizes idle time and ultimately leads to increased productivity [17]. Furthermore, investing in worker training and skill devel­
opment can significantly boost productivity in line balancing. Well-trained worker’s complete tasks more rapidly and with higher
quality, resulting in enhanced overall efficiency and productivity across the production line [18]. Lastly, technological advancements,
such as automation and robotics, play a pivotal role in elevating productivity in line balancing. Automated production lines can
operate continuously, resulting in substantial productivity increases. Furthermore, the integration of robotics to perform repetitive
tasks enables human workers to redirect their efforts towards more complex and skill-intensive activities [19].
In summary, several strategies exist to enhance productivity in line balancing, including resource allocation optimization, efficient
task sequencing, worker training, and technological innovation. By prioritizing these strategies, manufacturing companies can in­
crease productivity and profitability while upholding high standards of quality and customer satisfaction.

1.1.3. Efficiency
Efficiency in line balancing refers to the extent to which the production line can achieve maximum output while minimizing waste
and idle time. When a production line is efficiently balanced, each workstation is staffed appropriately, and the work is sequenced in
such a way as to minimize the time taken to complete each task.
Efficiency serves as a valuable way to gauge productivity, and it offers more meaningful insights than raw productivity numbers. It
provides a practical means of assessing performance against scientifically established targets. These targets are typically expressed in
terms of time per garment or specific production levels, simplifying the calculation of efficiency. These targets are usually set at a
performance benchmark of 100 %. So, when an operator reaches their target production, their efficiency stands at 100 %. Conversely,
if they achieve only 50 % of their target, their efficiency is 50 %. This efficiency-focused approach provides a more meaningful
assessment of performance in manufacturing settings. The formula for calculating line efficiency is presented in Equation (2).
(Output per day per line) ∗ (standard time)
Line efficiency = ∗ 100 (2)
(man power per line) ∗ (working minutes per day)
Efforts to improve efficiency in line balancing encompass a range of strategies drawn from multiple sources [20–24]. These
strategies can be summarized as follows:

1. Reducing Idle Time: Idle time occurs when workers or machines wait for the next task or workstation to become available. Effi­
ciency can be significantly enhanced by minimizing idle time. This is typically achieved by distributing the workload evenly across
workstations, ensuring each worker has a sufficient number of tasks.
2. Sequencing Tasks Efficiently: The sequence in which tasks are performed within the production process is critical for improving line
balancing efficiency. Logical and efficient task arrangement can reduce the time required for each task, resulting in overall effi­
ciency gains.
3. Addressing Bottlenecks: Bottlenecks occur when one workstation or process lags behind others, causing a backlog of work.
Identifying and eliminating bottlenecks within the production line is crucial for improving overall efficiency.
4. Worker Training: Worker training plays a vital role in enhancing efficiency. Well-trained workers operate more efficiently and
maintain higher quality standards, contributing to increased productivity across the entire production line.
5. Technology Adoption: Integrating advanced technologies such as automation, robotics, or AI can significantly enhance efficiency
by optimizing various aspects of the production line, ultimately working toward the goal of improved line balancing efficiency.

Incorporating these strategies collectively enhances the effectiveness of line balancing operations, resulting in increased efficiency
and productivity.

1.1.4. Efficiency improvement techniques in garment manufacturing

Line balancing, a technique for distributing tasks evenly among workers and machines, boosts efficiency in production lines [25]. It
not only standardizes work completion times but also increases output while reducing the need for both manpower and machinery. The
technique’s effectiveness is evidenced by a study showing a rise in production efficiency from 44 % to 53 % following its imple­
mentation [25]. Line balancing plays a significant role in lean manufacturing, contributing greatly to the optimization of production
efficiency [26,27].
Cellular manufacturing is one of the techniques for efficiency improvement, and it helps to create a single, smooth flow. This

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approach grants businesses the flexibility to offer a diverse range of products to their clients by grouping similar items into categories,
which can be processed using the same machinery in an identical sequence. Cellular manufacturing benefits factories because it de­
creases waste and overproduction, shortens lead times, boosts efficiency and quality, and fosters better communication and teamwork
[28].
Lean principles, centered around continuous improvement and enhancing employee performance, are cost-effective strategies for
boosting efficiency. In the garment industry, these principles have proven to be especially valuable for operational enhancement
without requiring large investments [27]. In lean principles, 5S is one approach to organizing, ordering, cleaning, standardizing, and
continuously improving a work area in the garment manufacturing industry [29].
The operator skill matrix is instrumental in enhancing efficiency in the garment industry by ensuring tasks align with workers’
skills, resulting in optimized performance. It also maintains records of operators’ previous performances to guide future task as­
signments [30].
Productivity in the garment industry can be improved through techniques like time study, visual management, and work standards
[31]. These methods led to an 8.07 % increase in efficiency, and specialized operator training further reduced time consumption and
enhanced productivity [32].

1.1.5. Time study

Time study involves employing specific methods to ascertain the average time a skilled or moderately experienced worker requires
to finish a task at a particular work pace [33]. It helps estimate the standard time for an activity, defined as the duration a trained
operator takes to accomplish a task efficiently using prescribed methods, tools, and workplace setups under certain conditions. This
standard time is pivotal in “work measurement,” a process essential for operational planning and control. Without such data, eval­
uating facility capacity and estimating delivery dates or costs becomes impractical [34].

1.1.6. Line balancing

Line balancing, a critical aspect of assembly line efficiency, involves distributing workload evenly among tasks within a cell or
value stream. This practice is essential for optimizing assembly line performance [6]. In the garment manufacturing sector, line
balancing encompasses the strategic distribution of sewing machines customized to meet the distinct style and design prerequisites of
individual garments. The approach adopted is contingent on the nature and type of garment being produced [6].
Implementing time study methods and fully utilizing worker capacity can lead to notable efficiency improvements in the sewing
section. For instance, through line balancing, a T-shirt production line’s productivity improved from 45.3 % to 58 %, and efficiency
increased from 54.22 % to 59.74 % [35].
The process of assembling apparel can be challenging due to the numerous operations involved in the sewing line, and the varying
working capacities of different individuals. Improving productivity and quality involves identifying and mitigating the factors that
affect them, leading to enhancements in both production and quality [16].

1.1.7. Techniques of line balancing

Line balancing is a crucial technique employed in manufacturing to optimize the allocation of resources and ensure the efficient
utilization of workstations within the production line [36,37]. Several techniques are commonly used in line balancing:

1. Precedence Diagramming: This technique involves the creation of a diagram that illustrates the sequence of tasks necessary to
complete a product or process. By analyzing this diagram, the order of tasks can be optimized to minimize the time spent on each
one.
2. Task Grouping: Task grouping entails the consolidation of tasks into clusters that can be executed by a single worker. This method
reduces the need for multiple workers, resulting in decreased downtime and improved overall efficiency.
3. Cycle Time Analysis: Cycle time analysis is centered on evaluating the duration needed to accomplish each task along the pro­
duction line. Optimizing the cycle time of each task contributes to improving the overall efficiency of the production line.
4. Heuristic Approaches: Heuristic approaches rely on practical rules of thumb and best practices to optimize the production line. For
instance, the longest task time heuristic involves assigning the longest task to the workstation with the most available time.
5. Time Studies: Time studies involve direct observation and measurement of the time taken to complete individual tasks within the
production line. Analyzing the results of time studies enables the identification and resolution of bottlenecks and inefficiencies.
6. Computer Simulation: Using computer simulation, organizations can create virtual production line models to assess various line
balancing scenarios. This enables them to identify the most efficient technique, enhancing overall production line effectiveness.

1.1.8. Modeling and simulation in line balancing

Modeling refers to the act of constructing a representation, often called a model, of a system, process, or phenomenon with the
purpose of studying it and making predictions. This practice is common in the business world, where modeling is employed for
analyzing, optimizing, and predicting various processes or systems [38]. The primary goal of a model is to enable analysts to foresee
how changes will affect the system. Therefore, a model should closely mimic the real system, encompassing its critical elements. In
today’s industries, models are essential tools. They allow for the development of virtual representations of intricate systems or pro­
cesses, which are then subjected to simulations. This approach offers a robust way to test multiple scenarios and make predictions
under diverse conditions [39]. In the context of garment manufacturing, simulation has gained paramount importance, delivering
substantial benefits to both line balancing and the broader production processes [9]. The following advantages are particularly

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noteworthy:

1. Identifying bottlenecks: Simulation helps to identify bottlenecks in the manufacturing process by providing a visual representation
of the entire production line. This helps manufacturers to pinpoint areas where the flow of production is impeded and take
corrective measures to improve efficiency.
2. Analyzing process efficiency: Simulation enables garment manufacturers to analyze the efficiency of the production process by
providing real-time data on production rates, cycle times, and operator utilization. This method empowers manufacturers to assess
how alterations in the production line affect overall performance, thereby facilitating more informed decision-making and
optimization.
3. Reducing downtime: Simulation can help to reduce machine downtime by identifying potential issues early on, allowing manu­
facturers to take proactive steps to prevent breakdowns and reduce maintenance requirements. This results in increased machine
uptime, productivity, and profitability.
4. Optimizing worker utilization: Simulation also helps to optimize worker utilization by providing data on worker performance,
identifying skill gaps, and suggesting training programs where necessary. This helps to ensure that workers are deployed to the
appropriate workstations, resulting in higher efficiency and productivity.
5. Cost-effective: Simulation helps to identify potential issues and implement changes without disrupting the actual production line.
This eliminates the need for costly trial-and-error processes, thus saving time, money, and resources

In a practical application, a study on trouser production used simulation to test different workstation layouts. Although it didn’t
factor in machine setup times and breakdowns, the insight gained was invaluable [26]. A line balancing algorithm was central to this
study, helping unveil the most efficient workstation configurations. Another study employed the Pro-Model simulation package,
delving into the modular system’s efficiency within the garment industry [40]. Even with the exclusion of factors like machine
downtime and the movement of operators between stations, the study still managed to provide significant insights. It underscored the
utility of simulation tools in improving productivity, optimizing machine and labor use, and enhancing inventory management.

2. Methodology

This research study focuses on Abay garment industry, aiming to investigate its operational efficiency. To achieve this, a quan­
titative research approach is employed, utilizing a case study design. The case factory specifically selects less efficient, yet highly
demanded production lines for analysis. These selected lines will be thoroughly analyzed to gain insights into their performance and
identify potential areas for improvement.

2.1. Data collection and analysis

2.1.1. Observation
Direct observation is a fundamental and significant method for collecting primary data in many research studies. It involves
carefully observing and documenting crucial information regarding material flow, job duration, manufacturing operation sequences,
and work procedures. This method plays a vital role in visualizing and gathering essential information related to these aspects of the
study.

2.1.2. Unstructured interview

Unstructured interviews were conducted to gather pertinent information. These interviews aimed to acquire data regarding various
aspects, including working hours, the quantity of machines, workforce allocation per operation, as well as work-related factors like the
duration of shifts, the utilization of machines, and the daily production output.

2.1.3. Tools and techniques

The study utilized Arena Simulation Software, specifically the Academic version 14, for modeling and analysis. Additionally,
various materials and tools, such as a stopwatch, spreadsheet software, calculator, paper, and pencils, were employed for testing and
evaluation.

Table 1
Preliminary sample for five activities.
Operation or activity Observation (Ẋ − xi)2

Heat cell 54.90 38.56

Placket attach 41.20 56.10
Lower placket top 40.38 69.05
Bottom hem 59.26 111.72
Vent take 47.70 0.98
Total 243.44 276.41
Mean (Ẋ) 48.69

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2.1.4. Sample size and time study

Sampling involves selecting a representative subset from the overall population in a research context [41]. For the ‘bracket attach’
operation, as illustrated in Table 1, five preliminary samples were considered to ascertain the requisite number of observations for
thorough data collection. Effective sampling is crucial in empirical research to prevent data errors or population biases. The primary
method is random sampling, which includes simple, stratified, cluster, systematic, and multistage techniques [42]. For the study, the
number of observations, the mean of the initial preliminary sample, and the standard deviation were calculated using Equations (3)–
(5), respectively.
( zs )2
n= (3)
hx
/
Ẋ=1 ∑ (4)
n
n xi
x− 1

√̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅
/
S= (xi − Ẋ)2 (n − 1)2 (5)

In this context, n represents the number of observations; x denotes the sample measured with a stopwatch; Ẋ is the mean of the
sample; S signifies sample standard deviation; half of the precision interval is represented by h. For example, for a ±5 % interval, h,
half of the precision interval is 0.1; and z represents the standard normal deviation associated with the specified confidence level.
Generally, in most industrial settings, a 95 % confidence level is adopted, for which the standard values are z = 2 and h = 0.1 [43].
√̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅
/
s = (276.41)2 (5 − 1)2 = 8.31
( zs )2 ( 2∗8.31 )2
n = hx = 0.1∗48.69 = 11.65 ≅ 12, cycle time is required for each operation.
Time Study Procedures: The process of conducting a time study is explained in Fig. 1.

2.2. Simulation modeling

2.2.1. Problem identification and conceptual model (flow chart)

The Abay Garment Industry in Gondar, Ethiopia, specializes in textile production, specifically weaving or knitting fibers to create

Fig. 1. Time study procedures.

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fabrics, with the finishing process of a polo shirt involving 29 steps carried out by both employees and machines, as shown in Fig. 2.
The company employs 37 workers and utilizes 29 machines, but a line balancing issue has been identified, resulting in a current
production output of about 285 products per shift, falling short of the target of exceeding 400 products per shift.
The study follows a four-phase approach to achieve its objectives. This is represented in a flow chart Fig. 3. In the first phase, the
researchers identify the problems and establish three main objectives, as outlined in the concluding paragraph of the introduction.
Moving on to the second phase, real data is collected using primary techniques such as observation and unstructured interviews. This
data is then translated into the Arena simulation software to develop the input and simulation model for the polo shirt operations. The
developed model is subsequently verified and validated to ensure its accuracy in representing the real system of Abay garment’s polo

Fig. 2. Flow process chart of Polo shirt.

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Fig. 3. Methodological approach for the study.

shirt operation. In the third phase, various scenarios are experimented with, and the results are observed. In the final phase, con­
clusions are derived from the results yielded by the simulation software.

2.2.2. Input modeling

The recorded data was analyzed using the input analyzer feature of the Arena software. This analysis aimed to determine the
distribution of the data, which would then be utilized in developing the simulation model within the Arena software. The distribution
serves as a function that defines the relationship between observations in the recorded sample space. Fig. 4 illustrates an example of the
processing time distribution for the heat cell and front mark operations. Additionally, Table 2 outlines the resource and operation time
distribution for all operations involved.

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Fig. 4. Heat cell (a) and front mark (b) processing time distribution.

2.2.3. Model development

The simulation model used the Arena® version 14.0 simulation software and was constructed based on a production diagram
provided by the case company, as shown in Fig. 2. The arrangement of sewing machines followed the diagram, while the line balancing
algorithm dictated the number of machines allocated to each operation.
The study employed discrete-event modeling, with the case company operating for 540 min (9 h) per day. There were approxi­
mately 29 operations and a labor force of around 37 individuals required for these operations. At the start of each order, the
manufacturing line was initially empty, a state that was replicated in the simulation. However, it is important to note that this initial
start-up condition could potentially introduce bias to the results, as the line requires time to stabilize and reach a steady state. Entities
queued for sewing machine usage were organized in a first-in-first-out system, awaiting availability of the resource. In the design of the
system, the following assumptions were taken into account:

• The manufacturing line is assumed to be empty at the beginning of each order.

Table 2
Resource and operation time distribution.
No Operations Machine types No of operators No of machine Expression

1 Heat cell Heat cell 1 1 31 + 24 * BETA (1.25, 1.04)

2 Front mark Manual 1 0 39 + 26 * BETA (0.722,0.531)
3 Shoulder attach Over Lock 1 1 31 + 19*BETA (0.75,0.942)
4 Placket mark Manual 1 0 9 + 13 * BETA (1.32, 1.31)
5 Placket attach Single Needle 1 1 NORM (32.3, 5.05)
6 Placket top and open Single Needle 1 1 19 + LOGN (10.5, 19.7)
7 Under placket top Single Needle 1 1 NORM (28.7, 7.18)
8 Lower placket top Single Needle 1 1 33 + LOGN (11.9, 15.8)
9 Boxer Single Needle 1 1 TRIA (46, 54.3, 76)
10 Bottom hem Over Lock 2 2 UNIF (63, 87)
11 Sleeve attach Over Lock 2 2 NORM (85.5, 6.42)
12 Side seam Over Lock 2 2 TRIA (60, 91.6, 117)
13 Venture Single Needle 1 1 TRIA (25, 30, 35)
14 Cuff Over Lock 1 1 UNIF (73, 90)
15 Vent take Single Needle 1 1 47 + ERLA (2.01, 2)
16 Vent close Single Needle 1 1 66 + EXPO (12.3)
17 Collar run Single Needle 1 1 25 + 26*BETA (1.02,0.632)
18 Collar top Single Needle 1 1 39 + GAMM (15, 1.14)
19 Collar stand hem Single Needle 1 1 TRIA (80, 93.2, 124)
20 Collar stand hem mark Manual 1 0 34 + GAMM (4.16, 1.52)
21 Collar run and Collar stand hem attach Single Needle 2 2 TRIA (22, 38.8, 46)
22 Collar stand top Single Needle 1 1 20 + 18 * BETA (1.17, 1.11)
23 Collar attach Single Needle 2 2 66 + WEIB (44.8, 1.23)
24 Collar close Single Needle 2 2 78 + 29*BETA (0.83,0.948)
25 Buttonhole Buttonholing 1 1 29 + 6*BETA (0.705,0.994)
26 Button attach mark Manual 1 0 UNIF (19, 44)
27 Button attach Button attaching 1 1 28 + 29 *BETA (0.543,0.707)
28 Thread trim Manual 3 0 98 + ERLA (5.95, 2)
29 Quality check Manual 1 0 29 WEIB (20.5, 1.17)

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• No maintenance work is conducted during working hours.

• Breaks are not included in the 540-min working time.
• Setup times are excluded from the system model, aligning with real-world practices where setups usually occur outside of working
hours.
• It is assumed that the polo shirt assembly line consistently receives a steady flow of input materials from the cutting section.

Considering all these factors, we have developed the current simulation model for the production of polo shirts, as depicted in
Fig. 5.

2.2.4. Number of replications

In simulation studies, the term ‘number of replications’ denotes how frequently a simulation is executed, each time with varying
randomly generated input parameters or initial conditions. The purpose of running multiple replications is to estimate the variability in
the simulation output and to reduce the impact of random noise on the results.
The number of replications needed in a simulation study is contingent upon several factors, including the complexity of the
simulation model and the degree of variability present in the input parameters and the desired level of precision in the output esti­
mates. Generally, the more replications that are run, the more precise the estimates will be, but this comes at the cost of increased
computational time and resources. A prevalent method for ascertaining the suitable number of replications involves performing a
power analysis, which estimates the necessary sample size to attain a specified degree of statistical power. This analysis takes into
account the expected effect size, the variability in the input parameters, and the desired level of significance. Therefore, to determine
the required number of replication number the first 10 outputs has been extracted from the first ten replications as mentioned in
Table 3. Then, using mathematical techniques the replication number is determined.
In various fields, a 95 % confidence level (equivalent to a 5 % statistical significance level) is commonly employed for data rep­
resentation. The standard deviation reflects the extent of variation in the results of the replications from their mean. The half-width
represents a sampling error incurred during the sampling process and can be calculated using the standard error. To achieve a 95 %
confidence level, the t value is derived from the table of t-distribution, yielding a t value of 2.262.
The half-widths (h0 ) of the polo production line is determined as follows:
( )
(t ∗ σ) 2.262 ∗ 0.948
h0 = √̅̅̅ = √̅̅̅̅̅ = 0.678.
n 10
Consequently, the percentage error for polo shirt production lines equal to:
Percentage error = [(mean value + half width)/mean] − 100 %

= [(293.3 + 0.678)/293.3]-100%

= 1.0023–100 % = 0.0023.
Therefore, by using the replication number equations:

Fig. 5. Existing simulation model of the polo shirt production.

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M.M. Teshome et al. Heliyon 10 (2024) e23585

Table 3
The number of polo shirt output for the first ten replications.
Number of replications Number of polo shirt outputs

1 293
2 292
3 293
4 292
5 293
6 294
7 293
8 294
9 295
10 294
Mean 293.3
Standard deviation (S) 0.948

a 2) / 2 ( )/ 2
n = (Z2 1 − s h and n = no ∗ ho2 h
2
( ) ( )
Where h = 14 ∗ h0 = h = 14 ∗ 0.678 = 0.1695
Actual replication of the polo shirt:
( 2 )
Z ∗ 0.975 ∗ S2
n= ,
h2
( )
1.962 ∗ (0.948)2
n=
(0.1695)2

n = 120 option 1
( )/
n = no∗ ho2 h2
( )/
n = 10∗0.6782 0.16952

n = 160 option 2
Consequently, among the two presented options, the maximum number of replications chosen is 160.

2.2.5. Model verification and validation

Validation and verification are crucial steps in simulation modeling. If the model fails to accurately represent the real system, the
reliability and quality of decisions based on its outputs may be compromised. Thus, to ensure that this model accurately mirrors the
behavior of the production line, it is essential to conduct thorough verification and validation. In the test run, the model operated
seamlessly across various input settings, particularly with adjustments in arrival times, and did not generate any errors or warnings.
The process animations were monitored, confirming the accuracy of the path. Given that the test run proceeded without issues,
indicating a smooth, uninterrupted operation of the production line within the model, it can be concluded that this model is verified
and effectively represents the real system.
To affirm the model’s reliability, its output was compared with that of the real system. This was achieved by performing a test run,
during which a comprehensive comparison was conducted between the output values of the model and those of the existing system to
ensure their alignment. As the actual data indicates, the company can produce 285 parts per shift on average. The simulation result of
the existing system that considers 9 h of working time and a 160-repliction number is about 293, which is close to the actual output,
mathematically the validity of the model can be checked as follows:

Model Error (%) = [(SimulationValue-ActualSystemValue)/ActualSystemValue]x 100%

( )
293 − 285
= ∗ 100 = 2.8% which is less than 5%
285
The ARENA model used in this study is considered valid based on the acceptable error criterion set by certified analysts from
Rockwell Automation, which is ±5 %. This error margin ensures the reliability and accuracy of the model.

2.3. Line balancing

Line balancing involves allocating sewing machines based on the style and design of a garment, tailored to the specific type of

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M.M. Teshome et al. Heliyon 10 (2024) e23585

garment being produced. Therefore, after the standard allowed minute (SAM) has been determined by the work measurement tech­
niques, the line balance can be used, allowing the following procedure as mentioned below in Fig. 6.

2.3.1. Line balancing procedure

.

2.3.2. Key performance measures

Vital metrics for evaluating the success of an organization or team are provided by Key Performance Measures (KPMs). This study
adopts KPMs from relevant literature, covering aspects like daily output, operations, required operators, line efficiency, labor pro­
ductivity, costs, revenue, and profits. These metrics provide a comprehensive assessment, aiding informed decisions and
enhancements.

2.3.3. Line balancing scenarios

In line balancing research, scholars often examine different scenarios to address specific issues and align with their research goals.
These scenarios are drawn from existing literature and applied in this study, encompassing strategies like adding extra time, merging
operations, adding resources, optimizing worker allocation, and task distribution. Each scenario offers a potential solution to line
balancing challenges, adaptable to specific study or real-world needs.

3. Results and discussion

3.1. Standard allowed minute calculation

When considering work tasks, it is essential to prioritize taking breaks. Even the most skilled operators require time to rest or attend
to personal needs. Consequently, it is crucial to account for break allowances when determining standard times for operations. In this
regard, three types of allowances are considered: relaxation allowance (11 % for sitting jobs), machine allowances for specific machine
types (Single needle lock stitch: 12.5 %, Overlock stitch: 12 %, Double needle lock stitch: 14 %), and contingency allowance (5 %) [44].
These allowances are applied separately from the rating factor to ensure accurate calculations.
In this study, close collaboration was established with the company’s management team to determine appropriate allowances. After
thorough consideration, a total allowance of 15 % was designated for manual operations. Additionally, operators using single needle
machines were allotted a 28.5 % allowance, while operators utilizing overlock machines received a 28 % allowance. This approach
guarantees that our standard times accurately reflect the realities of operators’ day-to-day work.
For the third operation, known as “Shoulder attach,” which involves using an overlock machine, we have calculated the standard
time using the procedure outlined below. This same procedure has been applied to all the subsequent operations.
Observed time = 50 s
observed performance
Rating factor =
normal performance

= 329/350 = 0.94

Fig. 6. Line balancing procedures.

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M.M. Teshome et al. Heliyon 10 (2024) e23585

Normal time = Average observed time (OT) × Rating factor (RF)

= 50 ∗ 0.94 = 47 seconds

Standard time (ST) = Normal time (NT) + Allowances time (AT)

= 47 + 0.28 = 47.28
Therefore, the same procedure has been taken for the remaining operations.

3.2. Base/existing simulation model

The results obtained from the simulation model offer valuable insights into the behavior of the system being studied. These results
enable us to assess the initial performance of the system and identify areas that require improvement. One significant key performance
indicator is the system output, which is illustrated in Table 5 and indicates that the number of polo shirts produced is 293 shirts.
However, this falls below the company’s target, highlighting the need for further enhancements.
The company operates for 9 h per day, and the performance metrics extracted from the existing simulation model are presented in
Table 5. The selling price of one polo shirt is 250 birr, while the monthly labor cost amounts to approximately 3300 birr. With a
workforce of 37 employees, the total monthly labor cost reaches 122,100 birr (37 workers * 3300 birr).
Revenue is calculated as Revenue = Sp × q, where Sp represents the selling price and q denotes the quantity produced.
Revenue = (250 ∗ 293) = 73, 250 birr
The same procedures were applied to the other scenarios to calculate the revenue and direct labor cost. Another important per­
formance measure to consider is the waiting time of parts in the queue. Table 4, derived from the simulation results of the current
system, identifies operations experiencing the highest waiting times. These include collar attachment with body, collar run, collar
stand hemming, front part marking, heat cell process, and side seam process. These operations are identified as bottleneck operations
due to their extended waiting times. Consequently, significant modifications in these processes can markedly reduce waiting times,
boost output numbers, enhance line efficiency, and improve labor productivity.

3.3. Line balancing scenario 1

Extending Replication by 30 Minutes for Workers with High Wait Times: To address the issue of high waiting times, a solution was
proposed to enhance the replication length by 30 min for workers experiencing this problem. Consequently, considering all the
conditions of the existing model, a second alternative was developed by allocating an additional 30 min for operations that are busy
and have high waiting times. Given that the sewing line operates for a single 9-h shift each day, the most practical window for
scheduling overtime is during the lunch break, specifically between 5:00 a.m. and 5:30 a.m. By incorporating this adjustment of 30 min
for the identified busy operations with high waiting times, the average output per shift of the system has increased. Further details and
performance measures are summarized in Table 5.

3.4. Line balancing scenario 2

Merge similar operations: Merging similar operations is a commonly employed technique in line balancing to enhance production
efficiency. This approach involves consolidating tasks or operations that share similarities and can be effectively executed by a single
workstation or machine instead of multiple ones. With this approach in mind and considering the conditions of the reference model, a
new model has been developed that merges operations utilizing similar resources. As a result, several operations have been merged in
the production process for increased efficiency. These merged operations include operations 6, 7, and 8; operations 17 and 18; op­
erations 21 and 22; operations 25 and 26; and operations 27 and 29. The outcomes of these mergers, along with pertinent details, are
presented and summarized in Table 5 for reference and analysis.

Table 4
Scenario analysis.
Scenario properties Controls Responses

No. Name Single Replication Single Single Over Collar attach Side seam System
needle 10 length needle 11 needle 12 lock 5 with body process queue number out
1 Existing 1.00 540.00 1.00 1.00 1.00 68.282 136.612 293.00
system
2 Scenario 1 1.00 570.00 1.00 1.00 1.00 75.885 144.856 326.00
3 Scenario 2 1.00 540.00 2.00 1.00 1.00 38.548 100.074 297.00
4 Scenario 3 1.00 540.00 1.00 2.00 2.00 0.012 1.918 343.00
5 Scenario 4 1.00 570.00 1.00 2.00 2.00 0.011 2.114 381.00

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M.M. Teshome et al. Heliyon 10 (2024) e23585

Table 5
Comparative study of the various scenarios.
Performance measures Existing scenario Scenario 1 Scenario 2 Scenario 3 Scenario 4

Average daily output 293 units 297 units 326 units 343 units 381 units
Total count of operations and machines 29 29 25 25 25
Total number of operators required for the 37 37 32 32 32
Line
Line efficiency 39.06 41.17 % 45.70 % 52.80 % 55.64 %
Labor productivity 54.25 % 57.20 % 55 % 63.50 % 66.80 %
Annual labor cost 122,100 birr/ 122,100 birr/ 105,600 birr/ 105,600 birr/ 105,600 birr/
month month month month month
Total revenue from the product 73,250 birr/day 81,500 birr/day 74,250 birr/day 85,750 birr/day 95,250 birr/day

3.5. Line balancing scenario 3

Resource Adjustment and Merging at High-Wait Stations: Considering all the conditions of the existing model, a third alternative
has been developed by merging similar operations and reallocating resources from idle operations to busy operations that experience
high resource utilization. In the sewing section, certain operations like collar run, attachment, stand hemming, front part marking, heat
cell processing, and side seam processing face considerable waiting times. Presently, these operations are allocated just a single
resource in the existing production line. To resolve this bottleneck, a strategy of merging and reallocating resources to these high-wait
operations has been implemented, simultaneously reducing resource allocation to operations experiencing higher idle times. As a
result, this model scenario leads to an increase in the system’s output from 298 to 343 shifts per day. Detailed performance measures
can be found in Table 5.

3.6. Line balancing scenario 4

Integrating Scenarios 2 and 3: This combined scenario emerges from the fusion of Scenarios 2 and 3, incorporating strategies for
merging operations with similar requirements and adjusting resource levels according to their usage. Moreover, an additional 30 min is
allocated to operations experiencing high demand. The outcomes of this integrated approach are detailed in Tables 4 and 5

3.7. Comparative study of the different scenarios

The aim of this research was to evaluate how line balancing affects production efficiency in a garment manufacturing setting. To
accomplish this, data was gathered both prior to and subsequent to the introduction of line balancing in a production line exclusively
dedicated to the manufacturing of polo shirts. The results indicate a substantial improvement in production efficiency following the
implementation of line balancing, as illustrated in Table 4 and Fig. 7.
The results demonstrate a significant change in the number of outputs and waiting times at the collar attach and side seam processes
between the existing system and the improved scenarios. The existing system produces 293 products and has waiting times of 68.2 min
at the collar attach with body process and 136.6 min at the side seam process.
In the first scenario, the number of outputs increases to 326 while the waiting times at the collar attach with body and side seam
processes are 75.5 min and 144.85 min respectively. The second scenario has 297 outputs and waiting times of 35.8 min and 100.074
min at the two processes. The third scenario produces around 343 products and reduces the waiting times at the collar attach with body
and side seam processes to around 0.012 min and 1.918 min respectively. Finally, the fourth scenario produces 381 products and has
waiting times of 0.011 min and 2.114 min at the two processes.

Fig. 7. Comparison of simulation outcomes across scenarios.

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M.M. Teshome et al. Heliyon 10 (2024) e23585

Overall, the enhanced scenarios demonstrate higher outputs and reduced waiting times compared to the existing system. Notably,
the fourth scenario excels, yielding the highest outputs and the shortest waiting times. For enhanced visual representation, these
comparisons are depicted in a bar chart, as shown in Fig. 7.
Table 5 presents an in-depth and comprehensive summary of the results obtained from the examination of four distinct scenarios.
This table delivers a clear and succinct presentation of the main findings, simplifying the process of comparing and analyzing the
results in a straightforward and systematic manner.
The implementation of line balancing has proven to be a highly effective strategy for improving production efficiency within the
context of this study. It has yielded substantial enhancements in various critical aspects of the production process, thereby contributing
to heightened overall efficiency and productivity. This achievement aligns closely with the overarching objective of optimizing
production operations. To comprehensively illustrate the beneficial impact of line balancing, the subsequent sections present detailed
results and supporting evidence:

1. Average Daily Output: The average daily output increased substantially, rising from 293 to 381 units.
2. Reduction in Operations and Machines: The number of operations and machines involved in the production process decreased,
going from 29 to 25, streamlining the overall process.
3. Decrease in the Number of Operators: Line balancing led to a reduction in the number of operators required, declining from 37 to
32, while maintaining efficiency.
4. Improved Line Efficiency: The line efficiency metric witnessed a notable improvement, surging from 39.06 % to 55.64 %, signifying
a more streamlined production process.
5. Enhanced Labor Productivity: Labor productivity exhibited a substantial boost, climbing from 54.25 % to 66.8 %, indicating more
efficient utilization of workforce resources.
6. Reduction in Direct Labor Costs: The direct labor cost associated with producing polo shirts witnessed a significant decrease,
dropping from 122,100 birr to 105,600 birr per month, which can contribute to cost savings.
7. Increased Company Revenue: The positive impact of line balancing extended to the company’s financial performance, with daily
revenue rising from 73,250 birr to 95,250 birr, reflecting enhanced profitability.

3.7.1. Output analyzer

To compare differences among scenarios, ANOVA analysis was performed at a 95 % confidence level. In Fig. 8a, the average waiting
time at the bottleneck operation “collar attach with body” is shown, where L1 represents the existing scenario and L5 represents the
fourth scenario. The mean values are statistically unequal, indicating the fourth scenario with the shortest waiting time. Similarly,
Fig. 8b illustrates waiting times in the side seam process queue, with differing mean values among scenarios, and the fourth scenario
displaying the shortest waiting time. Fig. 9 presents the number of system outputs, with distinct mean values among scenarios, and the
fourth scenario yielding the highest number of outputs.
In this study, ANOVA (analysis of variance) was used to compare mean values among various scenarios. Figs. 8 and 9 show unequal
mean values between these scenarios. This suggests that the fourth scenario reduces waiting times at bottleneck operations and in­
creases output. Consequently, implementing the fourth scenario improves production efficiency.
Previous studies have demonstrated the beneficial effects of combining line balancing with simulation in terms of production
efficiency, productivity, and system output, ultimately resulting in reduced waiting times. An example is a strategy that utilized the
OptQuest simulation tool to decrease waiting time and boost output [45]. This approach successfully reduced waiting time and
increased output. However, it should be noted that their approach relied on increasing resources, which can potentially lead to higher
labor costs.
Simulation has been effective in improving line balancing and increasing labor productivity, with notable results in areas like the
polo shirt assembly line [8,14]. Increased throughput and labor efficiency were also achieved using similar computer simulation
techniques [9].
Building on these previous studies, the present research sought to not only improve productivity, efficiency, and reduce waiting
times but also reduce labor costs and increase profits for the case company. Our findings align with previous research, indicating that
line balancing is an effective strategy for enhancing production efficiency. The suggested simulation model for balancing the pro­
duction line of polo shirts offers decision makers a simulation-driven optimization tool that enables them to acquire insights and
enhance system performance without disrupting the real system.
Additionally, the model allows managers to test new systems before implementation without disrupting real production. This tool
enables them to enhance system performance and gather insights without impacting the actual operational system. Moreover, the
model provides managers the ability to trial new systems prior to their implementation, ensuring no disruption to actual production
processes.
In summary, our study provides strong evidence that line balancing, integrated with simulation, can be a powerful tool for
improving production efficiency in manufacturing settings. By optimizing the allocation of tasks and resources, line balancing can
reduce waiting times, increase productivity, and significantly improve system output while reducing labor costs, ultimately leading to
increased profitability for the company.

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M.M. Teshome et al. Heliyon 10 (2024) e23585

Fig. 8. ANOVA output of waiting time comparison for collar attach (a) and side sim process (b).

Fig. 9. ANOVA system output of different scenarios.

4. Conclusion

This study focused on improving the productivity and line efficiency of Polo shirt production through the development of a line-
balancing model utilizing simulation techniques. The researchers began by meticulously determining the standard time for 29 different
operations through work measurement procedures and principles, and then developed a simulation model for the existing system
based on the standard allowed minutes. The simulation results revealed bottleneck operations, leading to the development, and testing
of four different scenarios. The fourth scenario proved the most effective, utilizing strategies such as merging similar operations,
adjusting resources, and adding extra time for busy operators.
The proposed line-balanced model brought significant improvements, including an increase in average daily output from 293 units
to 381 units, a reduction in the number of operations, machines, and operators, an enhancement in line efficiency from 39.06 % to
55.64 %, and an increase in labor productivity from 54.25 % to 66.8 %. The direct labor cost of producing polo shirts also reduced from
122,100 birr to 105,600 birr per month, while company revenue increased from 73,250 birr to 95,250 birr per day. These remarkable
results demonstrate that line balancing is a highly effective strategy for improving production efficiency.
In conclusion, line balancing plays a pivotal role in enhancing production and efficiency within garment factories. By optimizing
the allocation of tasks and resources, line balancing can help reduce bottlenecks, improve productivity, and enhance the quality of the
finished product. To achieve successful line balancing, it is essential to consider the unique requirements of each production line,
including worker skills, machine capabilities, and production targets. Regular monitoring and adjustment are also necessary to
maintain optimal line balancing and continuously improve the manufacturing process. In this study, our focus was on analyzing a
single line of polo shirt manufacturing using a simulation model. However, future researchers have the opportunity to expand upon

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M.M. Teshome et al. Heliyon 10 (2024) e23585

this work by exploring multi-line balancing utilizing various line balancing techniques. By implementing effective line-balancing
strategies, garment factories can enhance their competitiveness, meet market demand, and uphold high product quality standards.

5. Limitation of the study

This study is subject to certain limitations. To create a practical simulation model, simplifications and assumptions were made,
which may have impacted the accuracy and validity of the findings. Additionally, the precision needed for some time study goals may
not be achieved by using a stopwatch, which can only measure time in seconds or fractions of seconds. The rating factor was also
established using the researcher’s observations.

Data availability statement

The data supporting the findings of this study are included within the article, its supplementary materials, and are referenced
accordingly.

CRediT authorship contribution statement

Melkamu Mengistnew Teshome: Writing – review & editing, Visualization, Supervision, Project administration, Methodology,
Formal analysis, Investigation, Resources, Software, Validation, Data curation, Conceptualization. Tamrat Yifter Meles: Writing –
review & editing, Writing – original draft, Visualization, Validation, Supervision, Software, Resources, Project administration,
Methodology, Investigation, Formal analysis, Data curation, Conceptualization. Chao-Lung Yang: Writing – review & editing, Su­
pervision, Project administration, Investigation, Data curation, Formal analysis, Funding acquisition, Methodology, Resources, Soft­
ware, Validation, Visualization, Conceptualization.

Declaration of competing interest

The authors declare that they have no known competing financial interests or personal relationships that could have appeared to
influence the work reported in this paper.

Appendix A. Supplementary data

Supplementary data to this article can be found online at https://doi.org/10.1016/j.heliyon.2023.e23585.

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