Line balancing - Line Blancing and Production

LINE BALANCING Process Organization The Line Balancing is “ to design a smooth production flow by allotting processes to workers so as to allow each worker to complete the allotted workl

© SOFT Student Handouts,

By, Sunil Talekar, Faculty, SOFT-Pune

LINE BALANCING

LINE BALANCING (Process Organization) The Line Balancing is “ to design a smooth production flow

by allotting processes to workers so as to allow each worker to complete the allotted workload

within an even time”

Line: an assembly line composed of several work stations, at which specific operations are performed

To work effectively, with no work pile-ups between stations, the line must be

Line planning is scheduling and allocating of

orders to production lines according to product

setting (product is being made in the line) and

due dates of production completion

A line plan defines when a style is going to be

loaded to the line, how many pieces to be

expected (target) from the line and when order

to be completed For example, please refer to

the following Table-1, where a simple line

planning has been shown in spread sheet

WHAT IS LINE PLANNING?

Line 1 Line 2 Total Date Daily Prod Cumm Prod Daily Prod Cumm Prod Daily Prod.

1-Dec

loading #2341A, Qty -3000 pieces 300 1200 300 2-Dec 200 200 300 1500 500 3-Dec 250 450 300 1800 550 4-Dec 400 850 200 2000 600 5-Dec 400 1250

loading #Polo , Qty -1500 pieces 400

7-Dec 400 2050 100 100 500 8-Dec 400 2450 300 400 700 9-Dec 400 2850 350 750 750 10-Dec 150 3000 350 1100 500 11-Dec

loading #432K, Qty -5500 pieces 400 1500 400 12-Dec 100 100

loading #YK45, Qty -4500 pieces 100 13-Dec 250 350 200 200 450 14-Dec 500 850 250 450 750 15-Dec 500 1350 400 850 900 16-Dec 500 1850 400 1250 900 17-Dec 500 2350 400 1650 900 18-Dec 500 2850 400 2050 900 19-Dec 500 3350 400 2450 900 20-Dec 500 3850 400 2850 900 21-Dec 500 4350 400 3250 900 22-Dec 500 4850 400 3650 900 23-Dec 150 5000 400 4050 550

Daily Prod – Daily production or line output

Cumm Prod – Cumulative production of the style till date

UNBALANCED VS BALANCED

• Match the production rate after all wastes have been removed to the talk time at each process of the

value stream.

• Regular material flow.

• Maximum uses of man power and machine capacity.

• Minimum process time.

• Minimizing slack time.

• Minimizing workstation.

• Maximum output at the desired time.

• Quality maintenance of the garment.

• Reduce production cost

OBJECTIVES OF LINE BALANCING

• It helps production manager as well as line supervisor with

accordingly.

style would run, what is the next style going to be loaded?

BENEFIT OF LINE PLANNING

@ the main job in line balancing is to eliminate or reduce wip (work in process) at bottleneck operations.

@ keeps inventory costs low, resulting in higher net income

@ allows operator to work all day long giving an opportunity to earn more money and increases his/her work efficiency

@ keeps the prices low which turns into repeat sales

@ means better production planning

WHY LINE BALANCING…

IMPORTANCE OF LINE BALANCING

OPERATION NO 3

PRODUCTION 40 PIECES

1 MACHINE END DAY PRODUCTION 40 PIECES

OPERATION NO 2

PRODUCTION 45 PIECES

1 MACHINE END DAY PRODUCTION 40 PIECES

OPERATION NO 1

PRODUCTION 40 PIECES

1 MACHINE END DAY PRODUCTION 40 PIECES

LINE BALANCING AND PRODUCTION

OPERATION NO 4

PRODUCTION 80 PIECES

1 MACHINE END DAY PRODUCTION 40 PIECES

OPERATION NO 1

PRODUCTION 40 PIECES

1 MACHINE END DAY PRODUCTION 40 PIECES

OPERATION NO 2

PRODUCTION 45 PIECES

1 MACHINE END DAY PRODUCTION 40 PIECES

OPERATION NO 5

PRODUCTION 80 PIECES

1 MACHINE END DAY PRODUCTION 40 PIECES

there are 3 rules for balancing

at their maximum capacity

LINE BALANCING AND PRODUCTION

Production sheets

Daily production report

The inventory levels by operation

List down all operations with operator name as per operation

sequence

List down all operations with operator name as per operation

sequence

Check cycle time for each operation for five consecutive cycles

With average cycle time calculate hourly capacity of the operators

With average cycle time calculate hourly capacity of the operators

With the help of the hourly capacity, calculate the labour requirement

Step 1 Calculation Of The Labor Requirements and Capacity study

The Requirement Of Worker Depends Upon The Probable Efficiency Of The Line Selected And Percentage Of Time They Work

Line balancing in apparel manufacturing

STEPS TO A BALANCED LINE

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STANDARD ALLOWED MINUTES OF EACH OPERATION

+

STEPS TO A BALANCED LINE

Step 2 Operational breakdown and setting the Target

With the above step 1 & 2 data set your target output per hour from one

line.

With the above step 1 & 2 data set your target output per hour from one

line.

Generally it is calculated using following formula (Target per hour= Total

no of operators X 60 /garment SAM).

Generally it is calculated using following formula (Target per hour= Total

no of operators X 60 /garment SAM).

Check current hourly operator production report Draw a straight line with target output data on the line graph. 

Check current hourly operator production report Draw a straight line with target output data on the line graph. 

Step 3: Target setting

STEPS TO A BALANCED LINE

* The time at which the longest time is required is called “Bottleneck Process”

* The state of line organization should be evaluated as “Organization Efficiency”

* Pitch Time provides average time allotted to each worker.

* Using the pitch time and Bottleneck Process Time.

0 20 40 60 80 100 120 140

160 140

115 80

STEPS TO A BALANCED LINE

See picture of knitted trunk short, and develop operation breakdown and confirm possible bottleneck

Step 4 Identification of bottleneck areasH a n e s

Club operations where possible Give the operator another operation with less work content considering machine type and sewing thread colors. 

Club operations where possible Give the operator another operation with less work content considering machine type and sewing thread colors. 

Shuffle operators Operations that have low work content use low performer

while work content is higher use high performers.

Shuffle operators Operations that have low work content use low performer

while work content is higher use high performers.

Add more operators at bottleneck operations Also compare the cost-benefits

of putting additional machine into the line

Add more operators at bottleneck operations Also compare the cost-benefits

of putting additional machine into the line

Improve workstation layout and improve methods

Do extra work at bottleneck operations

Reduce cycle time using work aids and attachments

STEPS TO A BALANCED LINE

Methods of eliminating bottlenecks from the linestep4 Elimination of bottlenecks from the line

STEPS TO A BALANCED LINE

From Imbalanced line

TO BALANCED LINE

All in all…

Limitations of Line Balancing

the speed of the employees‟ work This arrangement wasn't

appreciated by the employees.

balance

STEPS TO A BALANCED LINE

Product: Full Sleeve Men’s Formal Shirt Brand: Arrow 

From given table draw a line diagram as well balance the line.

THANKS