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 t
Trang 1Line balancing
© SOFT Student Handouts,
By, Sunil Talekar, Faculty,
SOFT-Pune
© SOFT Student Handouts,
By, Sunil Talekar, Faculty,
SOFT-Pune
Trang 2What is line in apparel manufacturing?
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 balanced,
e.g work must get through each workstation in
roughly the same amount of time.
Trang 3What is Line Planning?
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.
During booking orders or allocating orders to the production line,
planners must check what is running on the line and how many days
it will take to complete the Running style.
Benefit of Line planning: It helps production manager as well as line supervisor with information such as what is the daily production
target for line They set their line (machines and manpower)
accordingly Line plan also provides information such as how many
days style would run, what is the next style going to be loaded?
Trang 4Line plan
Date Daily Prod. Cumm Prod. Daily Prod. Cumm Prod. Daily Prod.
1-Dec
loading #2341A,
5-Dec 400 1250 Qty -1500 piecesloading #Polo , 400
11-Dec Qty -5500 piecesloading #432K, 400 1500 400 12-Dec 100 100 Qty -4500 piecesloading #YK45, 100
Daily Prod – Daily production or line output
Cumm Prod – Cumulative production of the style till date
Trang 5LINE 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 BALANCING (Process Organization) It is a system where you meet the production expectations and you can find the same amount of work in process in every operation at any point in the day
Trang 6WHY LINE BALANCING…
@ 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
Trang 7Line balancing in apparel manufacturing
there are 3 rules for balancing
(1)have at least ½ hour of wip for each operation (2) Solve problems before they become any larger (3) Meet production goals by keeping every operator
working at their maximum capacity
Trang 8LINE BALANCING TOOLS
Production
sheets
Production
sheets
Daily production
report
Daily production
report
The inventory
levels by operation
The inventory
levels by operation
Production
boards
Production
boards
Stop watch Calculator
Trang 9Line balancing in apparel manufacturing
STEPS TO A BALANCED LINE
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.
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
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
With the help of the hourly capacity, calculate the labour requirement
Trang 10Line balancing in apparel manufacturing
STEP 2 OPERATIONAL BREAKDOWN AND SETTING THE TARGET
B.
• With the capacity data set target output per hour from one line
• With the capacity data set target output per hour from one line
C.
• Target per hour = Total no of operators X 60 /garment SAM
• Target per hour = Total no of operators X 60 /garment SAM
D.
• Current hourly operator production report is analyzed
• Current hourly operator production report is analyzed
STANDARD ALLOWED MINUTES OF EACH OPERATION
+
A
Trang 11Line balancing in apparel manufacturing
STEP 3: TARGET SETTING
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.
Trang 12* 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.
STEP 4 IDENTIFICATION OF BOTTLENECK AREAS
0 20 40 60 80 100 120 140
160 140
115 80
140
105
Bottleneck process
Name of worker (In order of processes)
See picture of knitted trunk short, and develop operation breakdown and confirm possible bottleneck
H a n e s
Trang 13STEP4 ELIMINATION OF BOTTLENECKS FROM THE LINE
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
Improve workstation layout and improve
methods
Do extra work at bottleneck operations
Reduce cycle time using work aids and
attachments
Reduce cycle time using work aids and
attachments
Methods of eliminating bottlenecks from the line
Trang 14Line balancing in apparel manufacturing
FROM IMBALANCED LINE
To Balanced line
All in all…
Trang 15Sl
No.
Operation List SAM
1 Pinning to profile 0.234
2 Run stitch collar 0.219
3 Trim collar 0.285
4 Clip and turn collar 0.223
5 Crease collar 0.381
6 Top stitch collar 0.42
7 Run stitch (R/s) collar band 0.291
8 Crease collar band 0.317
9 Insert collar in neck band 0.799
10 Turn and crease collar 0.452
11 Attach bias piece to cuff 0.874
12 Crease cuff 0.458
13 Hem cuff 0.501
14 R/s cuff 0.565
15 Trim cuff 0.36
16 Turn cuff 0.527
17 Crease cuff bottom 0.566
18 Attach placket to sleeve 0.795
19 Lock and make diamond 1.026
20 Sew pleats (4 no.) 0.389
21 Hem right front 0.494
22 Attach front placket 0.603
23 Crease pocket 0.542
24 Hem pocket mouth 0.28
25 Attach pocket to front 0.861
26 Attach brand label and tack loop 0.589
27 Crease patch pieces 0.236
28 Attach patch piece 0.333
29 Sew pleats 0.278
30 Attach yoke to back 0.475
31 Top stitch back yoke 0.365
32 Join shoulder 0.64
33 Top stitch shoulder 0.656
34 Attach collar 0.535
35 Close collar with size label 1.01
36 Sleeve attach 0.862
37 Top stitch armhole 0.678
38 Top stitch side seam 1.036
39 Attach & close cuff 0.696
40 Top stitch cuff 0.524
41 Hem bottom 0.947
Total SAM 22.322
Product: Full Sleeve Men’s Formal Shirt Brand: Arrow
From given table draw a line diagram as well balance the line.