OPTIMIZING WORKFORCE UTILIZATION AND LINE BALANCING IN SME TIE-DYE PRODUCTION: AN MPL-WP AND MPL-NWP MODELING APPROACH
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Abstract
This study proposed a mathematical model to optimize workforce utilization in Small and Medium-sized Enterprises (SMEs) operating multiple tie-dye production lines involving a total of 10 distinct jobs with processing times ranging from 15 to 60 minutes. Two assignment strategies were developed and compared: the Multiple Production Line with Worker Pool (MPL-WP) model, allowing workers to be flexibly assigned across production lines, and the Multiple Production Line without Worker Pool (MPL-NWP) model, restricting workers to specific lines. The models were formulated as binary integer programming problems incorporating processing time constraints, precedence relations, and takt time to ensure feasible production schedules. Using the Python-MIP optimization package, various scenarios with differing production demands and available times were solved to analyze the relationship among these factors and the required workforce size. Results were indicated that the MPL-WP model generally reduced the total number of workers needed by up to 25% compared to the MPL-NWP model, particularly under high-demand or time-constrained conditions. This has highlighted the operational benefits of worker flexibility in improving labor efficiency and reducing costs. Moreover, the findings were provided actionable insights for SMEs seeking to enhance productivity despite limited resources and fluctuating demands, reinforcing the practicality and relevance of flexible assignment models in real-world production planning.
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