This study deals with optimal layout design by line balancing using simulation modeling. Modeling and simulation are potential tools for analysis of the assembly lines like apparel of a garment manufacturing. Thus, the researchers have tried to experiment different controls, responses, constraints and different objectives using an opt quest in the arena tool. The experiment controls the resources of the assembly line process without affecting the real production system.
In this study the Arena software, auto cad and production operation management (POM) software are employed to model and measure the performance of the existing sewing line of the Ronny t-shirt model. The t-shirt has 12 major parts to be assembled. For each activity, the researcher has taken 15 sampling observations using stopwatch. All the collected data are statistically analyzed using arena input analyzer for statistically significance and determination of expressions to be used to the simulation modeling. Standard simulation model was developed and run for 160 replications. The result shows the line is operating with a line balance efficiency of 72.56%. In the course of action using Opt Quest different types of scenarios had been developed and the best one was selected from the different simulation scenarios with a line balance efficiency of 75.3% and the company saves 518,400 birr per year that spent for salary of the extra resources allocated to produce the 650 t-shirts. This arena simulation model has considered the production resources like machines four thread over locks, single needle locks, two needles flat locks, operators of the machines, quality checkers, trimmers, inter arrival time, batch arrival of parts, processing time of each activity, sequence of parts, testing different scenarios.