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Line Balancing
Line Balancing
Course agenda
• Introduction : What is line balancing?
• Where do we use line balancing?
• Example
• Line Balance – A simple example
• Pre-requisites for line balancing…
• The benefits of the pre-requisites
• Method
• Visual management
• Summary - flowchart
Introduction : What is line balancing?
Variation is ‘smoothed’
No one overburdened
No one waiting
1 2 3 4
10
5
1 2 3 4
Line Balance : Simple Example
1 2 3 4
10
5
Pre-requisites to line balancing…
Achieve CONSISTENCY in
operations
Highlight key
information Work Work Work
station 1 station 2 station 3
Quality check Safety precaution Std in process stock Qty of SIPS Takt Time Cycle time
NO MAIN STEP S NO OP ERATING DESCRIP TION Q S E KEY P OINTS TIME EXP LANATION/ EXAMP LES/ DIAGRAMS
P .P .E. JIGS/ TOOLS As per P EGS requirement REQUIRED CHECKS TRAINING COMMENTS
The benefits of the pre-requisites
Takt time
Standard Operations
The benefits of the pre-requisites
Calculate TAKT
Ops 3
TAKT 25hrs
TAKT = 25 hrs
Total work
content
Line Balance
Ratio
Line Balance
Efficiency
Method - capture current state
Calculate TAKT
1 Fit bracket A 10 3 4
1
Walk to bench 0 0 0
15
Machine 2 10 5
2
Inspect 10 4 2
KEY:
TOTAL Manual Walk
¨ISSUER
•COORDINATOR
MGR
ISSUER Auto Waiting
18 of 43
Method - capture current state
Constraint – customer
demand not being met
Calculate Takt time
30
Time the process 30
Takt (25 hrs)
25
20 15 17
Break down the 15
work elements
10
5
Current State
Ops 3
Calculate total work
Takt 25 hrs
content (stacked time) : 15 + 30 + 17 = 62 hrs
Total work
content 62 hrs
Line Balance
Ratio
Line Balance
Efficiency
Method - capture current state
Or alternatively …..
1. Identify the business area to be balanced 3. Break down each process by task
i. Use ‘post it’ notes
ii. Write on the process name
iii. Place on a board in sequence
2. Form small group with team leaders/ 4. Agree estimated time for each job and
operators number of operators involved
Is it 1, 5 or 10 hours
i. Estimate a time for each sub element (use a rough guide)
ii. Add up all the elements
iii. Write on the main ‘post it’ the total time and total operators
3
2
Number of operators 2 1 2 1 1
Calculate TAKT
• Lay all the ‘post its’ out in 3
2
sequence so that all of the 2 1 2 1 1
TAKT
Method - capture current state
Target Manpower = Total Work Content
Calculate Takt time Takt time
Line Balance
= 3 operators Efficiency
Method – capture current state
Line balance ratio = Total work content
Calculate Takt time No. of stations x longest operation
Current State
1 2 3
Calculate target Target
3
manpower
manpower
Line Balance Ratio = 62 hrs X 100
= 69% Takt 25 hrs
(3 x 30)
Calculate Line Stacked 62 hrs
Balance Ratio & time
Efficiency What could be achieved without Line Balance
69%
Line Balance Efficiency = 62 hrs X 100 Ratio
reducing waste and still meeting = 83%
(3 x 25) Line Balance
TAKT – simply REBALANCING!! Efficiency 83%
Method – balance to TAKT
30
30
Takt (25 hrs) 30
25 25
Takt (25 hrs)
25 25
17
20 15 20 12
15 15 Target 83%
10 10 Efficiency
5
5
1 2 3 1 2 3
example
Method – balance to TAKT
1. Identify the elements of work that exceed TAKT
Balance to TAKT
30
30
Reduce Non Value Takt (25 hrs)
Added and 25
17
eliminate waste 20 15
15
10
Re-allocate work &
5
re-balance
1 2 3
Update calculations
2. Refer to Standard Work Combination table
COMPANY DATE ORIGINATOR
CHECKED
PART NAME STANDARDISEDSECTION
WORK
PART NUMBER COMBINATION VOLUME
TABLE
Yes PROCESS
WORKING TIME
TAKT TIME
SEC
OPERATION TIMETAKT
OPERATION NAME
Can this SEQUENCE MANUAL
10AUTO
3 WAIT
4 WALK
0 A0 0 15
1
1 Fit bracket
be 2 10 5
10 4 2 2
Walk to bench
Machine 1
improved? Inspect
No
No
Complete work
instruction •
TOTAL
¨ISSUER
COORDINATOR
MGR
ISSUER
KEY:
Manual
Auto Walk
Waiting
(standardise) &
implement
3. Identify where work can be re-allocated
Method – balance to TAKT
Update calculations
3 2
2 1 2 1 1
10hrs 2 1
Yes 5hrs 5hrs
1hr
Can this 1 2 1 2 1 2 1 2
be
5 hrs 5 hrs 5 hrs 5 hrs
improved?
No
No
Complete work
instruction
(standardise) &
implement 3. Using the experience of the team
leaders/ operators, invite them to
rebalance the work to below TAKT
Method – Identify value added and non-value added
time
Waste
All other meaningless, non-essential
And don’t forget !! activities that do not add value to the
product you can eliminate immediately e.g.
looking for tools, waiting time
Method – Identify value added and non-value added
time
Traditional Focus
Lean Manufacturing
• Work Longer-Harder-Faster
• Improve the Value
• Add People or Equipment Stream to Eliminate
Waste
Value
Waste
Added
LEAD TIME
Method – reduce non-value added time and eliminate
waste
So, identify the category of work on the
Balance to TAKT
standard work combination table
COMPANY DATE ORIGINATOR CHECKED
1 Fit bracket A 10 3 4
Re-allocate work & 1
re-balance Walk to bench 0 0 0
15
Machine 2 10 5
2
Inspect 10 4 2
Update calculations 1
Yes
Can this
be
improved?
No
No
Complete work
instruction TOTAL
KEY:
Manual Walk
implement
29 of 43
Method – balance to TAKT
Or alternatively…
Balance to TAKT
Update calculations
Update calculations 1 2 3
Yes
Can this
be
improved?
No
No
Complete work
instruction Use red strips to
(standardise) & signify non-value
implement added work
Method - reduce non-value added time and eliminate
waste
Balance to TAKT
Non value added activity
Update calculations 1 2 3
improved?
No
No
Takt 27 hrs
Complete work
instruction Stacked 57 hrs
(standardise) &
Attack the time
implement red, Line Balance
redistribute Ratio
Balance to TAKT
30
Takt (25 hrs)
Reduce Non Value 25
Added and 20
eliminate waste 15
10
5
Re-allocate work &
re-balance
1 2 3
Update calculations
30
Takt (25 hrs)
25
Yes 20
Can this Operator freed
be 15 up for other
improved? 10 process or
No improvement
No 5
Complete work team
instruction 1 2 3
(standardise) &
implement
Method - update the calculations
Line balance ratio = Total work content
Balance to TAKT No. of stations x longest operation
1 2 Line Balance
92%
Ratio
Yes
Can this Line Balance Ratio = 44 hrs X 100
= 92%
Line Balance
88%
Efficiency
be (2 x 24)
improved?
No
No
Complete work
instruction Previous balance
Line Balance ratio= =4469%
Efficiency hrs X 100
= 88%
(standardise) &
implement
Improvement of 23% (2 x 25)
Method - Continuous Improvement
Continuously use
Update calculations waste elimination tools
Yes
Can this
be
improved? Value
No
Added Waste
Complete work
instruction
(standardise) &
implement LEAD TIME
Method - standardise
Highlight key
information Work Work Work
station 1 station 2 station 3
Quality check Safety precaution Std in process stock Qty of SIPS Takt Time Cycle time
NO MAIN STEP S NO OP ERATING DESCRIP TION Q S E KEY P OINTS TIME EXP LANATION/ EXAMP LES/ DIAGRAMS