Production Line Balancing

Productivity Improvement Project

 Objective

To educate production related staff on

production line balancing
 Production Line Status

Ø Unbalanced status
Ø Balanced status
 Overview

Ø Disadvantages due to improper line balancing

Ø Factors effected for unbalancing a production
line
Ø Steps to be followed - Line balancing
Ø Week Points to be improved
Ø Expected skill inventory after training
Ø Maintaining the proper line balancing
 Disadvantages
Improper line balancing
Ø Difficult to meet delivery date
Ø Under utilization of workers’ capacity
Ø Wastages
Ø Space
Ø Electricity
Ø Extra payments
Ø Extra workload
Ø Creating problems
 Higher Higher
Absentee Defective
ism Percentage
Poor
Higher Team
M/C Break Work
Down

Ignoranc Poor Data

e Recording &
Analysis
Higher
Labor Turn
Over Unskilled
Workers
 Steps to be followed - Line balancing
1. Daily Production Target
 Steps to be followed - Line balancing
2. Actual Available Time per operator per day

Spent Time Per Attendance

Day Rate
Efficiency

480 min 346min

 Steps to be followed…
3. Balance Time per operator per day

Target output per day = 770

Actual Available Time Per Operator Per Day = 346 minutes
 Steps to be followed…
3. Preparing the analysis sheet
( For Theoretical Manning Level – TML )
Balance
No Operation Machine Type SMV Calculation TML
Time

1 Back York O/L O/L 0.47 0.45 0.47 / 0.45 1.05

2 Back York Out Line D/N/L/S 0.43 0.45 0.43 / 0.45 0.96
3 Back Rise O/L O/L 0.39 0.45 0.39 / 0.45 0.87
4 Back Rise O/L Out Line D/N/L/S 0.41 0.45 0.41 / 0.45 0.91
5 Back Pocket Hem D/N/L/S 0.46 0.45 0.46 / 0.45 1.03
6 Back Pocket Attach D/N/L/S 0.95 0.45 0.95 / 0.12 2.12

TML – No. of mans, Perform in 100 rate

 Steps to be followed…
3. Preparing the skill inventory
( Actual Manning Level - AML - Performance)

Pocket Pocket F/R rise Pkt F/R waist Bow Bow Check
Side Seam F/R rise Pkt bag
Name E.P.F.NO Hem Attach Out line covering Marking Marking
SNLS OL DNLS H/P
Manosha 945 0.90 0.95 0.85 0.90
Lalani 449 0.75
Sunethra 330 0.75 0.65
Dayani 772 0.85
Nadeeka 957 0.90
Sanjeewani 969 0.70
Sriyani 357 0.70
Bimali 136 0.85
Indika 288 0.70 0.80
Indrani 156 0.65 0.75
Chandrika 999
Manjula 171 0.90 0.80
 Steps to be followed…
4. Matching AML values with TML values

Balance
TML AMLS Total AMLS AMLS- TML Comment
Time
0.45 1.05 0.00 0.00 -1.05 Not Available
0.45 0.96 0.69 0.69 -0.27 Less Capacity
0.45 0.87 0.84 0.84 -0.03 Well fitted
0.45 0.91 0.76 0.00 -0.91 Used
0.45 0.74 0.8, 0.93 0.8 0.06 Well fitted
0.45 0.47 0.74 0.74 0.27 Over Capacity
0.45 1.52 0.8, 0.85,0.78, 0.83 1.58 0.06 Many Operators
 Steps to be followed…
4. Line Balancing Graph
43
40 Over
37 Capaci
34
ty
31
28
25
22
Unavailab 19
nO
p
io
se
a

le
r
t

16
13
10 Merge
7 Point
4
1
-1.50 -1.00 -0.50 0.00 0.50 1.00

ManningLevel Difference
 Week Points to be improved

Ø Improper Layout
Ø Poor handling
Ø Improper work place arrangement
Ø Inadequate machine adjustments
 Expected skill inventory after training
O/PTYPE PANT JKT
M/CTYPE SNLS

FLYBOXATT WITHZIPPER
PKT BAG ATTTO FRONT
GRADE

EPFNO

FLAPATT & TSFLAP

FLYATT TO FRONT

CUT PKT OUT LINE

OPERATORNAME

LINING SHELLATT
CARGO PKTATT
TACKPKT BAG

COLLERCLOSE
BACKPKTATT

ZIPPERCLOSE
TSSIDE SEAM
TSBTM HEM

NECKCLOSE
FACING ATT

ZIPPERATT
TSWBTOP

WBCLOSE
WELT ATT

TSZIPPER
MAKE 'J'

TSCUFF
WBATT
A 969 NERANJALA 70 75 75 80 85 70 75 85 85 80
A 971 GEETHAMALA 80 75
A 1362 INDIKA 85
A 1458 YAMUNA 75 70 70 80 65 75 80 60 80
A 1469 SUJEEVE 75 100 75 75 70 70 75 82
B 1619 DEEPIKA 65 65 65 60 60 70 65
A 1773 SHIRANI 80 65 60 80 80 75 70
A+ 1823 INOKA 70 95 95 75 100 80 70 75 70 80 80
A 2056 DAYANI 80 85 65 90 75 65 80 60 90 85 80
A+ 2090 DAMAYANTHI 100 95 95 80 80 100 80 80
B 2144 SUGANDI 75 85 80 70 80
A+ 2414 UDENI 90 65 90 90 60
C 2486 NISANSALA 80
B 2819 SHANIKA 80 50 75 90 70
A+ 2913 PRIYANKA 80 80 70 90 90 75 75 80 90 80 80 80 75 70 80 80
 How to sustain an improved Line

Ø Update the skill inventory style wise

Ø Plan the operator training program by means of
the updated skill inventory
Ø Follow the correct line balancing method
Ø Eliminate factors affected to unbalance a
production line
Ø Higher M/C break down
Ø Control KPI values related to production line
Ø Absenteeism
Ø Labor turn over
 Summary

Ø Correct production line balancing method

Ø Guide to schedule the operator training program
Ø How to maintain a balanced production line
THANK
YOU