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Line Balancing and WIP
Line Balancing and WIP
Topics
1.
2.
3.
4.
5.
6.
Work in Progress
Balancing
Reasons of Balancing
Balancing: How to Start?
Balancing Tools
Balancing Matrix
1. Work in Progress/Process
1. WIP
Day1
Starting WIP
200 pieces
Output
1000 pieces
WIP
200+5000-1000 = 4200
pieces
Day 2
Cutting Issued to sewing
5500 pieces
Quality Rejection
100 pieces
Output
2000 pieces
WIP
4200+5500-2000 =7700
pieces
4
1. WIP
Front
Back
Loading
5000
5000
Output
2000
1500
50002000=3000
50001500=3500
Initial WIP
WIP
1. WIP
Front WIP
300
0
Back WIP
300
0
Assembly WIP
510
0
210
0
6
Total WIP
1. WIP
1. WIP
WIP is made up of all garments and their parts that are not
completely finished. For example a bundle of shirts that has
everything attached but has no bottom hem.
We can measure WIP in Units/Pieces or in units of time. For
example, if we know that an operation A takes 0.5 minutes per
unit to process and we have 5 bundles of 12 units each then we
have 30 minutes of WIP for that operation (5 X 12 X 0.5).
In some factories, some operations have days of inventory waiting to
be processed! This is unacceptable for many reasons.
High
Inventory/WIP
Inventory Hides Problem
2. Balancing
What is a balanced production system?
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It is very important that all supervisors put line balancing in their daily
plans
every day.
12
5. Balancing Tools
There are a number of tools that can be used for balancing.
These are applied according to the plants needs.
The most basic ones are
Production Sheets / Gum Sheet
Inventory levels by operation and bi-hourly production
monitoring
Production Boards
Daily sewing report
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5. Bi-Hourly Report
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HIGH
LOW
Transfer OUT
after WIP is
normal
Transfer IN
temporarily
Transfer IN +
BBB Follow-up
Transfer OUT
now
No Change
Transfer IN +
BBB Follow-up
WIP
Transfer OUT to
LOW
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Thank You
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