The single‐row machine layout problem in apparel manufacturing by hierarchical order‐based genetic algorithm

Purpose – Change of machine layout is often required for small quantity and diversified orders in the apparel manufacturing industry. The purpose of this paper is to use a hierarchical order‐based genetic algorithm to quickly identify an optimal layout that effectively shortens the distance among cutting pieces, thereby reducing production costs.Design/methodology/approach – The chromosomes of the hierarchical order‐based genetic algorithm consist of the control genes and the modular genes to acquire the parametric genes, a precedence matrix and a from‐to matrix to calculate the distance among cutting pieces.Findings – The paper used a men's shirt manufacturing as an example for testing the results of a U‐shaped single‐row machine layout to quickly determine an optimal layout and improve effectiveness by approximately 21.4 percent.Research limitations/implications – The manufacturing order is known. The machine layout is in a linear single‐row flow path. The machine layout of the sewing department is inde...