Professional Documents
Culture Documents
What+is+Line+Balancing+and+How+to+Achieve+It
What+is+Line+Balancing+and+How+to+Achieve+It
Line balancing is a production strategy that involves balancing operator and machine time
to match the production rate to the Takt time.
Takt time is the rate at which parts or products must be produced in order to meet customer
demand.
For a given production line, if production time is exactly equal to Takt time, then the line is
perfectly balanced. Otherwise, resources should be reallocated or rearranged to remove
bottlenecks or excess capacity. In other words, the quantities of workers and machines
assigned to each task in the line should be rebalanced to meet the optimal production rate.
Benefits of Line Balancing
Then, rearrange tasks to reduce excess capacity and bottlenecks. For example, move
resources–workers and equipment–from parts of the line that have excess capacity to
bottlenecks. In other words, aim to alleviate the workload where there are blockages, and
move it to places where excess capacity can be filled by absorbing more work. This will
reduce the waiting waste in the places where there was excess capacity. It will also help
improve production flow where there were bottlenecks.
Try to organize elementary tasks into groups that minimize operators’ idle time and that
maximize the utilization of machines and equipment. Share the workload among operators
in the most logical way, taking into account the data on operator performance that you
have gathered. Ideally, each group of tasks should be completed in the same amount of
time to achieve synchronization.
Consider if you have too many or too few workstations. Line balancing might improve
process efficiency to a point where there is excess capacity throughout your line. It might
be beneficial to remove workstations or combine processes.
Wherever you have several operators performing consecutive tasks and working as a unit,
you should strive to reduce the imbalance between workers and workloads. Proper
arrangement and allocation of tasks in production lines help maximize output at the desired
time.
Many Lean practices can also help reduce variation in your lines. 5S and visual
management create a coherent workspace, thus reducing the time wasted looking for tools
and improve=ing process efficiency. Poka-yoke, or error-proofing, a process helps catch
defects early, which increases the consistency of output.
Conclusions