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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
It is used as a tool to continuously drive out waste from operations and processes and it is also a valuable tool in implementing changes in customer demand,
Inventory
Waiting
Rework
Transportation
Motion
5 mins
25 mins
15 mins
10 mins
15 mins
15 mins
15 mins
10 mins
Achieve CONSISTENCY in operations Enabling us to achieve our customers requirements by managing our production effectively Variation in our operations demands more human intervention which, increases the risk of HUMAN ERROR
Standardise
Takt Time
Takt is a German word It describes the metronome
It is the principal that all activity within a business is synchronised by a pulse, set by the customer demand
Takt = total time available* total customer demand
Takt time
Customer demand = 10 units / month Total time available = 20 days Drumbeat = 1 part every 2 days Takt = total time available total customer demand
Every 2 days
Every 2 days
Every 2 days
Every 2 days
Every 2 days
Process 1
Process 2
Process 3
Process 4
Process 5
Customer
Standardise
Standard work layout
Operation sequence From: To: Cell/ Area Description: Part No.
Scale:
Capture the layout Indicate how the work flows Highlight key information
stores
Tool cabinet
Work station 1
Work station 2
Work station 3
Quality check
Safety precaution
Qty of SIPS
Takt Time
Cycle time
6
Name / position Date Name / position Date Name / position Date
Standardise
NO REVISION DATE PUM ME
SHEET..OF DATE:
PUM
ME
NO
MAIN STEPS
NO
OPERATING DESCRIPTION
KEY POINTS
TIME
P.P.E.
JIGS/ TOOLS
REQUIRED CHECKS
TRAINING COMMENTS
Standard Operations
Standard Operations provide: Capable and repeatable processes Process control at source Improves accuracy of planning Better adherence to plans A platform from which continuous improvement can be made Reduced costs Improved quality Basis for training
Customer demand = 19 units a month Time available = 20 days a month TAKT = Available time Customer demand TAKT = 20 days ( x 24 hrs in a day) 19 units
TAKT = 25 hrs
TAKT
Total work content
Line Balance Ratio Line Balance Efficiency
Why video? - Used to visually record activity - Accurate method of recording - Irrefutable and unambiguous - Modern approach to establishing method
1. 2. 3. 4.
Capture a representative sample of the process Review the video with the operators present Break down the elements of work and record a time for each one Identify which of the elements are Value-added and which are non-value added
The operators cycle is broken down into elements These elements are put into three main categories, these being : 1. 2. 3.
COMPANY PART NAME PART NUMBER PROCESS
WORKING SEQUENCE
TAKT
OPERATION NAME
OPERATION TIME
10 0 2 10
3 0 10 4
4 0 5 2
1 15 2
TOTAL
ISSUER ISSUER MGR COORDINATOR
Walk Waiting
18 of 43
30 25 20 15 17
15 10 5
3
Current State Ops 3 25 hrs 62 hrs
15 + 30 + 17 = 62 hrs
Takt
Total work content
Line Balance Ratio Line Balance Efficiency
Use post it notes Write on the process name Place on a board in sequence
Op1
2.
4.
i. ii. iii.
Agree estimated time for each job and number of operators involved
Estimate a time for each sub element (use a rough guide) Add up all the elements Write on the main post it the total time and total operators
3 2
1
Is it 1, 5 or 10 hours
2
5hrs
2
5hrs
10hrs
2
2
1hr
1
5 hrs
1
5 hrs
1
5 hrs
1 2
5 hrs
2 1
5hrs
Lay all the post its out in sequence so that all of the processes are visible Draw on the TAKT line (or use string)
3 2
5hrs
1
2 2
5hrs
1 1
10hrs
2
1hr
1 2
5 hrs
1 2
5 hrs
1 2
5 hrs
1 2
5 hrs
TAKT
20 15 10
3
Current State
Ops Takt
Total work content
3 25 hrs 62 hrs
= 2.48 = 3 operators
Total work content No. of stations x longest operation Total work content Target manpower x Takt
30 25 20 15 15 17
10 5
1
Calculate target manpower Line Balance Ratio Calculate Line Balance Ratio & Efficiency
Current State
Target manpower
= 62 hrs (3 x 30)
X 100
= 69%
What could be achieved without Line Balance Efficiency = 62 hrs X 100 reducing waste and still meeting = 83% (3 x 25) TAKT simply REBALANCING!!
30 25 20 15 10 5
25
25 12
example
1
Update calculations
2.
Can this be improved?
No No Yes
Walk Waiting
3.
2.
Update calculations
Yes
5hrs 1 2 5 hrs
3.
Using the experience of the team leaders/ operators, invite them to rebalance the work to below TAKT
Waste
And dont forget !!
All other meaningless, non-essential activities that do not add value to the product you can eliminate immediately e.g. looking for tools, waiting time
Value Added
Waste
LEAD TIME
So, identify the category of work on the standard work combination table
COMPANY DATE
ORIGINATOR CHECKED
TAKT
OPERATION NAME
OPERATION TIME
Fit bracket A 10
4 0 5 2
1 15 2
Update calculations
Yes
TOTAL
ISSUER ISSUER MGR COORDINATOR
Walk Waiting
29 of 43
Update calculations
Yes
Detail each process step (on format above) Indicate whether the work is : Wait Walk Work
Now you can split the operations on the board into elements of Value added and non value added work
Highlight the Value added and the non-value added work elements on the line balance board
30 25 20
Takt (25 hrs) Non value added activity Value added activity 1 2 3
15 10 5
Update calculations
Yes
15 10 5
Update calculations
3
Future State Ops Takt Stacked time
Line Balance Ratio Line Balance Efficiency 2
Yes
Reduce the NVA activity by applying waste removal tools (changeover reduction, 5C, process mapping etc)
27 hrs 57 hrs
25 20 15 10
Update calculations
30 25 Yes
20 15 10 5
Total work content No. of stations x longest operation Total work content Target manpower x Takt
Future State Ops Takt
Total work content 2
20 15 10
Update calculations
1
Can this be improved?
No No Yes
2
X 100
= 44 hrs (2 x 24)
= 92%
Previous Balance Efficiency ==44 hrs 69% Line balance ratio Improvement of 23% (2 x 25)
X 100
= 88%
Act
Plan
A P
Check
Do
Update calculations
Value Added
Method - standardise
Standard work layout
Operation sequence From: To: Cell/ Area Description: Part No.
Scale:
Capture the NEW layout Indicate how the work flows Highlight key information
Tool cabinet
Work station 1
Work station 2
Work station 3
Quality check
Safety precaution
Qty of SIPS
Takt Time
Cycle time
6
Name / position Date Name / position Date Name / position Date
Method - standardise
NO REVISION DATE PUM ME
SHEET..OF DATE:
PUM
ME
NO
MAIN STEPS
NO
OPERATING DESCRIPTION
KEY POINTS
TIME
P.P.E.
JIGS/ TOOLS
REQUIRED CHECKS
TRAINING COMMENTS
Method - standardise
Task Description Cycle Time
Time
finish
3
Root end chop lugs
4
Root end chop lugs Root end chop lugs
5
Root end chop lugs Root end chop lugs
6
Root end chop lugs Root end chop lugs
7
Root end chop lugs Root end chop lugs
8
Root end chop lugs Root end chop lugs
9
Root end chop lugs Root end chop lugs
10
Root end chop lugs Root end chop lugs
11
Root end chop lugs Root end chop lugs
12
Root end chop lugs Root end chop lugs
13
Root end chop lugs Root end chop lugs
14
Root end chop lugs Root end chop lugs
15
16
17
1 2 3 4 5 6 7 8 9
Takt Time
30
25
20
10
15
Root end Root chop end lugs chop Root lugs end Root chop end lugs chop lugs Root end Root chop end lugs chop lugs Root end Root chop end lugs chop lugs Root end Root chop end lugs chop lugs
Root end chop lugs Root end chop lugs Root end chop lugs
Root end chop lugs Root end chop lugs Root end chop lugs
Root end chop lugs Root end chop lugs Root end chop lugs
Root end chop lugs Root end chop lugs Root end chop lugs
Root end chop lugs Root end chop lugs Root end chop lugs
Root end chop lugs Root end chop lugs Root end chop lugs
Root end chop lugs Root end chop lugs Root end chop lugs
Root end chop lugs Root end chop lugs Root end chop lugs
Root end chop lugs Root end chop lugs Root end chop lugs
Root end chop lugs Root end chop lugs Root end chop lugs
Root end chop lugs Root end chop lugs Root end chop lugs
Root end chop lugs Root end chop lugs Root end chop lugs
Operator
Visual Management
The new line balance chart should be displayed on the cell The impact of changes in resource or Takt on operator cycle times can be seen instantly Opportunities for Kaizen activities can be easily identified
Summary
Capture the current state
Calculate Takt time
Current State
Operators
5hrs
Reduce Non Value Added and eliminate waste Future State Ops Re-allocate work & re-balance Takt
Total work content Line Balance Ratio 2
Takt
Total work content
Line Balance Efficiency Line Balance Ratio
25 hrs 62 hrs 69% 83% Calculate target manpower Draw current state Line Balance
Update calculations
Yes