Line balancing and its formulation
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Oct 13, 2016
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About This Presentation
Line balancing and how the productivity can be optimized through the help of formula and by working of 4Ms
Slide Content
Line Balance of a
manufacturing plant
(Assembly)
manufacturing plant
(Assembly)
By Avijit Biswas
Course agendaCourse agenda
• 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
Course agendaCourse agenda
• 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
By Avijit Biswas
Introduction : What is line balancing?
Everyone is doing the same
amount of work
Doing the same amount of work to
customer requirement
No one overburdened
No one waiting
Everyone working together in a
BALANCED fashion
Variation is ‘smoothed’
What is
Line
Balancing
Introduction : What is line balancing?
Everyone is doing the same
amount of work
Doing the same amount of work to
customer requirement
No one overburdened
No one waiting
Everyone working together in a
BALANCED fashion
Variation is ‘smoothed’
What is
Line
Balancing
By Avijit Biswas
Introduction : What is line balancing?
Introduction : What is line balancing?
By Avijit Biswas
Introduction : What is line balancing?
Single Piece Flow
Introduction : What is line balancing?
Single Piece Flow
By Avijit Biswas
Example : Example : Line Balance ChartLine Balance Chart
This is a VISUAL production tool that enables the planning and
organisation of individual, TIMED items of work to create the
foundation for a balanced production line.
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,
Example : Example : Line Balance ChartLine Balance Chart
This is a VISUAL production tool that enables the planning and
organisation of individual, TIMED items of work to create the
foundation for a balanced production line.
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,
By Avijit Biswas
Line Balance : Simple Example
1 2 3 4
25 mins5 mins 15 mins 10 mins
Constraint
Overburden
This operator
must WAIT for
operator 2
Overproduction which
causes the other 6
wastes
Waiting
Over-processing
Inventory
Rework
Transportation
Motion
This operator
must WAIT for
operator 3
5
10
15
20
25
1 2 3 4
mins
Line Balance : Simple Example
1 2 3 4
25 mins5 mins 15 mins 10 mins
Constraint
Overburden
This operator
must WAIT for
operator 2
Overproduction which
causes the other 6
wastes
Waiting
Over-processing
Inventory
Rework
Transportation
Motion
This operator
must WAIT for
operator 3
5
10
15
20
25
1 2 3 4
mins
By Avijit Biswas
Line Balance : Simple Example
5
10
15
20
25
Redistribute the work
1 2 3 4
15 mins15 mins 15 mins 10 mins
Promotes one-
piece FLOW
Avoids
overburden
Minimises the 7
wastes
Reduces
Variation
Line Balance : Simple Example
5
10
15
20
25
Redistribute the work
1 2 3 4
15 mins15 mins 15 mins 10 mins
Promotes one-
piece FLOW
Avoids
overburden
Minimises the 7
wastes
Reduces
Variation
By Avijit Biswas
Pre-requisites to line balancing…
StandardiseStandardise
Calculate TaktCalculate Takt
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
Understand the ‘drumbeat’
of the CUSTOMER
Pre-requisites to line balancing…
StandardiseStandardise
Calculate TaktCalculate Takt
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
Understand the ‘drumbeat’
of the CUSTOMER
By Avijit Biswas
Takt Time
Takt is a German word
It is the principal that all activity within a business is
synchronised by a pulse, set by the customer
demand
It describes the metronome
Takt = total time available*
total customer demand
Takt Time
Takt is a German word
It is the principal that all activity within a business is
synchronised by a pulse, set by the customer
demand
It describes the metronome
Takt = total time available*
total customer demand
By Avijit Biswas
Customer demand = 10 units / month
Total time available = 20 days
Drumbeat = 1 part every 2 days
Each process needs to complete one unit every 2 days
Process 1 Process 2 Process 3 Customer
Every 2
days
Process 4 Process 5
Takt time
Takt = total time available
total customer demand
Every 2
days
Every 2
days
Every 2
days
Every 2
days
Customer demand = 10 units / month
Total time available = 20 days
Drumbeat = 1 part every 2 days
Each process needs to complete one unit every 2 days
Process 1 Process 2 Process 3 Customer
Every 2
days
Process 4 Process 5
Takt time
Takt = total time available
total customer demand
Every 2
days
Every 2
days
Every 2
days
Every 2
days
By Avijit Biswas
Standardise
Highlight key
information
Operation
sequence
From:
To:
Cell/ Area
Description: Part No.
Quality check Safety precautionStd in process stock
Qty of SIPS Takt Time Cycle time
Standard work layout
Name / position DateName / position DateName / position Date
Scale:
stores
Work
station 1
Work
station 2
Tool
cabinet
PPE MUST BE
WORN AT ALL
TIMES
6
Work
station 3
Capture the layout
Indicate how the
work flows
Standardise
Highlight key
information
Operation
sequence
From:
To:
Cell/ Area
Description: Part No.
Quality check Safety precautionStd in process stock
Qty of SIPS Takt Time Cycle time
Standard work layout
Name / position DateName / position DateName / position Date
Scale:
stores
Work
station 1
Work
station 2
Tool
cabinet
PPE MUST BE
WORN AT ALL
TIMES
6
Work
station 3
Capture the layout
Indicate how the
work flows
By Avijit Biswas
Standardise
NO REVISION DATE
LOCATION: SHEET……..OF………
DEPT: DATE:
PREPARED BY:
AUTHORISATION:
WORK INSTRUCTION SHEET
OPERATION NO. OPERATION DESCRIPTION
NO MAIN STEPS QSE KEY POINTS EXPLANATION/ EXAMPLES/ DIAGRAMS
P.P.E. JIGS/ TOOLS REQUIRED CHECKS TRAINING COMMENTS
TIME
MEPUM
WP HRS
PEGS REF:
TLTL TL PUM ME
OPERATING DESCRIPTIONNO
As per PEGS requirement
Standardise
NO REVISION DATE
LOCATION: SHEET……..OF………
DEPT: DATE:
PREPARED BY:
AUTHORISATION:
WORK INSTRUCTION SHEET
OPERATION NO. OPERATION DESCRIPTION
NO MAIN STEPS QSE KEY POINTS EXPLANATION/ EXAMPLES/ DIAGRAMS
P.P.E. JIGS/ TOOLS REQUIRED CHECKS TRAINING COMMENTS
TIME
MEPUM
WP HRS
PEGS REF:
TLTL TL PUM ME
OPERATING DESCRIPTIONNO
As per PEGS requirement
By Avijit Biswas
The benefits of the pre-requisites
Takt time
Standard Operations
What do you think
are the benefits?
The benefits of the pre-requisites
Takt time
Standard Operations
What do you think
are the benefits?
By Avijit Biswas
Takt time maximises the productivity due to:
•Easily managed processes
•Output of each process matches customer demand
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
The benefits of the pre-requisites
Takt time maximises the productivity due to:
•Easily managed processes
•Output of each process matches customer demand
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
The benefits of the pre-requisites
By Avijit Biswas
Method - capture current state
Customer demand = 19 units a month
Time available = 20 days a month
TAKT = Available time
Customer demand
TAKT = 25 hrs
TAKT = 20 days
19 units
( x 24 hrs in a day)
TAKT
Total work
content
Line Balance
Ratio
Line Balance
Efficiency
25hrs
Current State
Ops 3
Calculate TAKT
Method - capture current state
Customer demand = 19 units a month
Time available = 20 days a month
TAKT = Available time
Customer demand
TAKT = 25 hrs
TAKT = 20 days
19 units
( x 24 hrs in a day)
TAKT
Total work
content
Line Balance
Ratio
Line Balance
Efficiency
25hrs
Current State
Ops 3
Calculate TAKT
By Avijit Biswas
Method - capture current state
Why video?
- Used to visually record activity
- Accurate method of recording
- Irrefutable and unambiguous
- Modern approach to establishing method
4.Identify which of the elements are Value-added
and which are non-value added
1.Capture a representative sample of the process
2.Review the video with the operators present
3.Break down the ‘elements’ of work
and record a time for each one
Calculate TAKT
Time the process
Method - capture current state
Why video?
- Used to visually record activity
- Accurate method of recording
- Irrefutable and unambiguous
- Modern approach to establishing method
4.Identify which of the elements are Value-added
and which are non-value added
1.Capture a representative sample of the process
2.Review the video with the operators present
3.Break down the ‘elements’ of work
and record a time for each one
Calculate TAKT
Time the process
By Avijit Biswas
Method – capture current state
Calculate Takt time
Time the process
Break down the
work elements
g
The operators cycle is broken down into elements
These elements are put into three main categories, these being :
1.Working (man or machine)
2.Walking
3.Waiting
COMPANY DATE
ORIGINATOR CHECKED
PART NAME SECTION
PART NUMBER VOLUME
PROCESS TAKT TIME
SEC
WORKING
SEQUENCE
MANUAL AUTO WAIT WALK
KEY:
Manual Walk
ISSUER ¨ COORDINATOR ¨ MGR ¨ ISSUER Auto Waiting
TIME
OPERATION TIMEOPERATION NAME
STANDARDISED WORK
COMBINATION TABLE
TOTAL
103 4
1
1042
15
2
0 00
1Fit bracket A
Walk to bench
Inspect
1
Machine 2105
TAKT
18 of 43
Method – capture current state
Calculate Takt time
Time the process
Break down the
work elements
g
The operators cycle is broken down into elements
These elements are put into three main categories, these being :
1.Working (man or machine)
2.Walking
3.Waiting
COMPANY DATE
ORIGINATOR CHECKED
PART NAME SECTION
PART NUMBER VOLUME
PROCESS TAKT TIME
SEC
WORKING
SEQUENCE
MANUAL AUTO WAIT WALK
KEY:
Manual Walk
ISSUER ¨ COORDINATOR ¨ MGR ¨ ISSUER Auto Waiting
TIME
OPERATION TIMEOPERATION NAME
STANDARDISED WORK
COMBINATION TABLE
TOTAL
103 4
1
1042
15
2
0 00
1Fit bracket A
Walk to bench
Inspect
1
Machine 2105
TAKT
18 of 43
By Avijit Biswas
Method - capture current state
Calculate total work
content (stacked time) : 15 + 30 + 17 = 62 hrs
Takt
Line Balance
Ratio
Line Balance
Efficiency
25 hrs
62 hrs
Current State
Ops 3
Total work
content
Constraint – customer
demand not being met
30
25
20
15
10
1 2 3
5
Takt (25 hrs)
15
30
17
Draw current state
Line Balance
Calculate Takt time
Time the process
Break down the
work elements
Method - capture current state
Calculate total work
content (stacked time) : 15 + 30 + 17 = 62 hrs
Takt
Line Balance
Ratio
Line Balance
Efficiency
25 hrs
62 hrs
Current State
Ops 3
Total work
content
Constraint – customer
demand not being met
30
25
20
15
10
1 2 3
5
Takt (25 hrs)
15
30
17
Draw current state
Line Balance
Calculate Takt time
Time the process
Break down the
work elements
By Avijit Biswas
Method - capture current state
Or alternatively …..
1.Identify the business area to be balanced
Machining Treatments Assembly
4.Agree estimated time for each job and
number of operators involved
i. Estimate a time for each sub element
ii.Add up all the elements
iii.Write on the main ‘post it’ the total time and total operators
Is it 1, 5 or 10 hours
(use a rough guide)
Total estimated time
Number of operators
1
5 hrs
2
2
5hrs
1
3
1
5 hrs
2
2
5hrs
1
1
5 hrs
2
2
10hrs
1
1
5 hrs
2
2
1hr
1
3.Break down each process by task
i. Use ‘post it’ notes
ii.Write on the process name
iii.Place on a board in sequence
Op1
Op 2
Sub
elements
of work
Main
process
steps
2.Form small group with team leaders/
operators
Method - capture current state
Or alternatively …..
1.Identify the business area to be balanced
Machining Treatments Assembly
4.Agree estimated time for each job and
number of operators involved
i. Estimate a time for each sub element
ii.Add up all the elements
iii.Write on the main ‘post it’ the total time and total operators
Is it 1, 5 or 10 hours
(use a rough guide)
Total estimated time
Number of operators
1
5 hrs
2
2
5hrs
1
3
1
5 hrs
2
2
5hrs
1
1
5 hrs
2
2
10hrs
1
1
5 hrs
2
2
1hr
1
3.Break down each process by task
i. Use ‘post it’ notes
ii.Write on the process name
iii.Place on a board in sequence
Op1
Op 2
Sub
elements
of work
Main
process
steps
2.Form small group with team leaders/
operators
By Avijit Biswas
Method - capture current state
1
5 hrs
2
2
5hrs
1
3
1
5 hrs
2
2
5hrs
1
1
5 hrs
2
2
10hrs
1
1
5 hrs
2
2
1hr
1
• Lay all the ‘post its’ out in
sequence so that all of the
processes are visible
• Draw on the TAKT line (or use
string)
TAKT
Calculate TAKT
Time the process
Draw current state
Line Balance
Break down the
work elements
2
5hrs
1
Method - capture current state
1
5 hrs
2
2
5hrs
1
3
1
5 hrs
2
2
5hrs
1
1
5 hrs
2
2
10hrs
1
1
5 hrs
2
2
1hr
1
• Lay all the ‘post its’ out in
sequence so that all of the
processes are visible
• Draw on the TAKT line (or use
string)
TAKT
Calculate TAKT
Time the process
Draw current state
Line Balance
Break down the
work elements
2
5hrs
1
By Avijit Biswas
Method - capture current state
Target Manpower = Total Work Content
Takt time
= 2.48
= 3 operators
Takt time = 25 hrs
Total work content = 62 hrs
30
25
20
15
10
1 2 3
5
Takt (25 hrs)
15
30
17
Calculate Takt time
Time the process
Draw current state
Line Balance
Calculate target
manpower
Break down the
work elements
Takt
Line Balance
Ratio
Line Balance
Efficiency
25 hrs
62 hrs
Current State
Ops 3
Total work
content
Method - capture current state
Target Manpower = Total Work Content
Takt time
= 2.48
= 3 operators
Takt time = 25 hrs
Total work content = 62 hrs
30
25
20
15
10
1 2 3
5
Takt (25 hrs)
15
30
17
Calculate Takt time
Time the process
Draw current state
Line Balance
Calculate target
manpower
Break down the
work elements
Takt
Line Balance
Ratio
Line Balance
Efficiency
25 hrs
62 hrs
Current State
Ops 3
Total work
content
By Avijit Biswas
Method – capture current state
Line balance ratio = Total work content
No. of stations x longest operation
Line balance Efficiency = Total work content
Target manpower x Takt
Line Balance Ratio = 62 hrs
(3 x 30)
X 100
= 69%
Line Balance Efficiency = 62 hrs
(3 x 25)
X 100
= 83%
Takt
Stacked
time
Line Balance
Ratio
Line Balance
Efficiency
25 hrs
62 hrs
Current State
Target
manpower
3
69%
83%
What could be achieved without
reducing waste and still meeting
TAKT – simply REBALANCING!!
30
25
20
15
10
1 2 3
5
Takt (25 hrs)
15
30
17
Calculate Takt time
Time the process
Draw current state
Line Balance
Calculate Line
Balance Ratio &
Efficiency
Calculate target
manpower
Break down the
work elements
Method – capture current state
Line balance ratio = Total work content
No. of stations x longest operation
Line balance Efficiency = Total work content
Target manpower x Takt
Line Balance Ratio = 62 hrs
(3 x 30)
X 100
= 69%
Line Balance Efficiency = 62 hrs
(3 x 25)
X 100
= 83%
Takt
Stacked
time
Line Balance
Ratio
Line Balance
Efficiency
25 hrs
62 hrs
Current State
Target
manpower
3
69%
83%
What could be achieved without
reducing waste and still meeting
TAKT – simply REBALANCING!!
30
25
20
15
10
1 2 3
5
Takt (25 hrs)
15
30
17
Calculate Takt time
Time the process
Draw current state
Line Balance
Calculate Line
Balance Ratio &
Efficiency
Calculate target
manpower
Break down the
work elements
By Avijit Biswas
Method – balance to TAKT
example
Target 83%
Efficiency
30
25
20
15
10
1 2 3
5
Takt (25 hrs)
15
30
17
1 2 3
25 25
12
Takt (25 hrs)30
25
20
15
10
5
Method – balance to TAKT
example
Target 83%
Efficiency
30
25
20
15
10
1 2 3
5
Takt (25 hrs)
15
30
17
1 2 3
25 25
12
Takt (25 hrs)30
25
20
15
10
5
By Avijit Biswas
Method – balance to TAKT
Update calculations
Balance to TAKT
Reduce Non Value
Added and
eliminate waste
Re-allocate work &
re-balance
Can this
be
improved?
No
Yes
Complete work
instruction
(standardise) &
implement
No
30
25
20
15
10
1 2 3
5
Takt (25 hrs)
15
30
17
1.Identify the elements of work that exceed TAKT
2.Refer to Standard Work Combination table
3.Identify where work can be re-allocated
COMPANY DATE ORIGINATORCHECKED
PART NAME SECTION
PART NUMBER VOLUME
PROCESS TAKT TIMESEC
WORKING
SEQUENCE MANUALAUTOWAITWALK
KEY:
Manual Walk
ISSUER ¨ COORDINATOR ¨ MGR ¨ ISSUER Auto Waiting
TIME
OPERATION TIMEOPERATION NAME
STANDARDISED WORK
COMBINATION TABLE
TOTAL
1034
1
1042
15
2
000
1Fit bracket A
W alk to bench
Inspect
1Machine
2105
TAKT
Method – balance to TAKT
Update calculations
Balance to TAKT
Reduce Non Value
Added and
eliminate waste
Re-allocate work &
re-balance
Can this
be
improved?
No
Yes
Complete work
instruction
(standardise) &
implement
No
30
25
20
15
10
1 2 3
5
Takt (25 hrs)
15
30
17
1.Identify the elements of work that exceed TAKT
2.Refer to Standard Work Combination table
3.Identify where work can be re-allocated
COMPANY DATE ORIGINATORCHECKED
PART NAME SECTION
PART NUMBER VOLUME
PROCESS TAKT TIMESEC
WORKING
SEQUENCE MANUALAUTOWAITWALK
KEY:
Manual Walk
ISSUER ¨ COORDINATOR ¨ MGR ¨ ISSUER Auto Waiting
TIME
OPERATION TIMEOPERATION NAME
STANDARDISED WORK
COMBINATION TABLE
TOTAL
1034
1
1042
15
2
000
1Fit bracket A
W alk to bench
Inspect
1Machine
2105
TAKT
By Avijit Biswas
Method – balance to TAKT
Or alternatively……
1.Refer to the ‘post it’
notes on the wall
3.Using the experience of the team
leaders/ operators, invite them to
rebalance the work to below TAKT
2.Use magnetic strips to signify the ‘post
it’ notes (elements of time)
1
5 hrs
2
2
5hrs
1
3
1
5 hrs
2
2
5hrs
1
1
5 hrs
2
2
10hrs
1
1
5 hrs
2
2
1hr
1
Update calculations
Balance to TAKT
Reduce Non Value
Added and
eliminate waste
Re-allocate work &
re-balance
Can this
be
improved?
No
Yes
Complete work
instruction
(standardise) &
implement
No
Method – balance to TAKT
Or alternatively……
1.Refer to the ‘post it’
notes on the wall
3.Using the experience of the team
leaders/ operators, invite them to
rebalance the work to below TAKT
2.Use magnetic strips to signify the ‘post
it’ notes (elements of time)
1
5 hrs
2
2
5hrs
1
3
1
5 hrs
2
2
5hrs
1
1
5 hrs
2
2
10hrs
1
1
5 hrs
2
2
1hr
1
Update calculations
Balance to TAKT
Reduce Non Value
Added and
eliminate waste
Re-allocate work &
re-balance
Can this
be
improved?
No
Yes
Complete work
instruction
(standardise) &
implement
No
By Avijit Biswas
Method – Identify value added and non-value added
time
What is Value added and non-value
added time?
Value Adding:
Any process that changes the
nature, shape or characteristics
of the product, in line with
customer requirements e.g
machining, assembly
Non-Value Adding,but unavoidable
with current technology or methods.
Any work carried out that does not increase
product value e.g inspection, part movement,
tool changing, maintenance
Waste
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
And don’t forget !!
Method – Identify value added and non-value added
time
What is Value added and non-value
added time?
Value Adding:
Any process that changes the
nature, shape or characteristics
of the product, in line with
customer requirements e.g
machining, assembly
Non-Value Adding,but unavoidable
with current technology or methods.
Any work carried out that does not increase
product value e.g inspection, part movement,
tool changing, maintenance
Waste
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
And don’t forget !!
By Avijit Biswas
Method – Identify value added and non-value added
time
Value
Added
Waste
Traditional Focus
•Work Longer-Harder-Faster
•Add People or Equipment
Lean Manufacturing
•Improve the Value
Stream to Eliminate
Waste
LEAD TIME
Method – Identify value added and non-value added
time
Value
Added
Waste
Traditional Focus
•Work Longer-Harder-Faster
•Add People or Equipment
Lean Manufacturing
•Improve the Value
Stream to Eliminate
Waste
LEAD TIME
By Avijit Biswas
Method – reduce non-value added time and
eliminate waste
Update calculations
Balance to TAKT
Reduce Non Value
Added and
eliminate waste
Re-allocate work &
re-balance
Can this
be
improved?
No
Yes
Complete work
instruction
(standardise) &
implement
No
COMPANY DATE
ORIGINATOR CHECKED
PART NAME SECTION
PART NUMBER VOLUME
PROCESS TAKT TIME
SEC
WORKING
SEQUENCE
MANUALAUTO WAIT WALK
KEY:
Manual Walk
ISSUER ¨ COORDINATOR ¨ MGR ¨ ISSUER Auto W aiting
TIME
OPERATION TIMEOPERATION NAME
STANDARDISED WORK
COMBINATION TABLE
TOTAL
1034
1
1042
15
2
0 00
1Fit bracket A
Walk to bench
Inspect
1
Machine 2105
TAKT
So, identify the category of work on the
standard work combination table
29 of 43
Method – reduce non-value added time and
eliminate waste
Update calculations
Balance to TAKT
Reduce Non Value
Added and
eliminate waste
Re-allocate work &
re-balance
Can this
be
improved?
No
Yes
Complete work
instruction
(standardise) &
implement
No
COMPANY DATE
ORIGINATOR CHECKED
PART NAME SECTION
PART NUMBER VOLUME
PROCESS TAKT TIME
SEC
WORKING
SEQUENCE
MANUALAUTO WAIT WALK
KEY:
Manual Walk
ISSUER ¨ COORDINATOR ¨ MGR ¨ ISSUER Auto W aiting
TIME
OPERATION TIMEOPERATION NAME
STANDARDISED WORK
COMBINATION TABLE
TOTAL
1034
1
1042
15
2
0 00
1Fit bracket A
Walk to bench
Inspect
1
Machine 2105
TAKT
So, identify the category of work on the
standard work combination table
29 of 43
By Avijit Biswas
Method – balance to TAKT
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
Update calculations
Balance to TAKT
Reduce Non Value
Added and
eliminate waste
Re-allocate work &
re-balance
Can this
be
improved?
No
Yes
Complete work
instruction
(standardise) &
implement
No
Or alternatively…
Method – balance to TAKT
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
Update calculations
Balance to TAKT
Reduce Non Value
Added and
eliminate waste
Re-allocate work &
re-balance
Can this
be
improved?
No
Yes
Complete work
instruction
(standardise) &
implement
No
Or alternatively…
By Avijit Biswas
Method – reduce non-value added time and
eliminate waste
Update calculations
Balance to TAKT
Reduce Non Value
Added and
eliminate waste
Re-allocate work &
re-balance
Can this
be
improved?
No
Yes
Complete work
instruction
(standardise) &
implement
No
Highlight the Value added and the non-value
added work elements on the line balance board
Non value added activity
Value added activity
Takt (25 hrs)
1 2 3
5
30
25
20
15
10
Use red strips to
signify non-value
added work
Method – reduce non-value added time and
eliminate waste
Update calculations
Balance to TAKT
Reduce Non Value
Added and
eliminate waste
Re-allocate work &
re-balance
Can this
be
improved?
No
Yes
Complete work
instruction
(standardise) &
implement
No
Highlight the Value added and the non-value
added work elements on the line balance board
Non value added activity
Value added activity
Takt (25 hrs)
1 2 3
5
30
25
20
15
10
Use red strips to
signify non-value
added work
By Avijit Biswas
Method - reduce non-value added time and
eliminate waste
Takt
Stacked
time
Line Balance
Ratio
Line Balance
Efficiency
27 hrs
57 hrs
Future State
Ops
2
Non value added activity
Value added activity
•Reduce the NVA activity by applying
waste removal tools (changeover
reduction, 5C, process mapping etc)
Attack the
red,
redistribute
the green !!
1 2 3
5
30
25
20
15
10
Takt (25 hrs)
Update calculations
Balance to TAKT
Reduce Non Value
Added and
eliminate waste
Re-allocate work &
re-balance
Can this
be
improved?
No
Yes
Complete work
instruction
(standardise) &
implement
No
Method - reduce non-value added time and
eliminate waste
Takt
Stacked
time
Line Balance
Ratio
Line Balance
Efficiency
27 hrs
57 hrs
Future State
Ops
2
Non value added activity
Value added activity
•Reduce the NVA activity by applying
waste removal tools (changeover
reduction, 5C, process mapping etc)
Attack the
red,
redistribute
the green !!
1 2 3
5
30
25
20
15
10
Takt (25 hrs)
Update calculations
Balance to TAKT
Reduce Non Value
Added and
eliminate waste
Re-allocate work &
re-balance
Can this
be
improved?
No
Yes
Complete work
instruction
(standardise) &
implement
No
By Avijit Biswas
Method – re-allocate & re-balance
1 2 3
5
30
25
20
15
10
Takt (25 hrs)
1 2 3
5
30
25
20
15
10
Takt (25 hrs)
Operator freed
up for other
process or
improvement
team
Update calculations
Balance to TAKT
Reduce Non Value
Added and
eliminate waste
Re-allocate work &
re-balance
Can this
be
improved?
No
Yes
Complete work
instruction
(standardise) &
implement
No
Method – re-allocate & re-balance
1 2 3
5
30
25
20
15
10
Takt (25 hrs)
1 2 3
5
30
25
20
15
10
Takt (25 hrs)
Operator freed
up for other
process or
improvement
team
Update calculations
Balance to TAKT
Reduce Non Value
Added and
eliminate waste
Re-allocate work &
re-balance
Can this
be
improved?
No
Yes
Complete work
instruction
(standardise) &
implement
No
By Avijit Biswas
Method - update the calculations
Update calculations
Balance to TAKT
Reduce Non Value
Added and
eliminate waste
Re-allocate work &
re-balance
Can this
be
improved?
No
Yes
Complete work
instruction
(standardise) &
implement
No
Line balance ratio = Total work content
No. of stations x longest operation
Line balance Efficiency = Total work content
Target manpower x Takt
Line Balance Ratio = 44 hrs
(2 x 24)
X 100
= 92%
1 2
5
30
25
20
15
10
Takt (25 hrs)
Line Balance Efficiency = 44 hrs
(2 x 25)
X 100
= 88%
Previous balance ratio =
69%
Improvement of 23%
Takt
Total work
content
Line Balance
Ratio
Line Balance
Efficiency
25 hrs
44 hrs
Future State
Ops
2
92%
88%
Method - update the calculations
Update calculations
Balance to TAKT
Reduce Non Value
Added and
eliminate waste
Re-allocate work &
re-balance
Can this
be
improved?
No
Yes
Complete work
instruction
(standardise) &
implement
No
Line balance ratio = Total work content
No. of stations x longest operation
Line balance Efficiency = Total work content
Target manpower x Takt
Line Balance Ratio = 44 hrs
(2 x 24)
X 100
= 92%
1 2
5
30
25
20
15
10
Takt (25 hrs)
Line Balance Efficiency = 44 hrs
(2 x 25)
X 100
= 88%
Previous balance ratio =
69%
Improvement of 23%
Takt
Total work
content
Line Balance
Ratio
Line Balance
Efficiency
25 hrs
44 hrs
Future State
Ops
2
92%
88%
By Avijit Biswas
Method - Continuous Improvement
Update calculations
Balance to TAKT
Reduce Non Value
Added and
eliminate waste
Re-allocate work &
re-balance
Can this
be
improved?
Yes
Complete work
instruction
(standardise) &
implement
No
Value
Added Waste
LEAD TIME
Continuously use
waste elimination
tools
P
DC
A
Plan
DoCheck
Act
Method - Continuous Improvement
Update calculations
Balance to TAKT
Reduce Non Value
Added and
eliminate waste
Re-allocate work &
re-balance
Can this
be
improved?
Yes
Complete work
instruction
(standardise) &
implement
No
Value
Added Waste
LEAD TIME
Continuously use
waste elimination
tools
P
DC
A
Plan
DoCheck
Act
By Avijit Biswas
Method - standardise
Highlight key
information
Operation
sequence
From:
To:
Cell/ Area
Description: Part No.
Quality check Safety precautionStd in process stock
Qty of SIPS Takt Time Cycle time
Standard work layout
Name / position DateName / position DateName / position Date
Scale:
stores
Work
station 1
Work
station 2
Tool
cabinet
PPE MUST BE
WORN AT ALL
TIMES
6
Capture the NEW
layout
Indicate how the
work flows
Scale:
stores
Tool
cabinet
Work
station 3
Method - standardise
Highlight key
information
Operation
sequence
From:
To:
Cell/ Area
Description: Part No.
Quality check Safety precautionStd in process stock
Qty of SIPS Takt Time Cycle time
Standard work layout
Name / position DateName / position DateName / position Date
Scale:
stores
Work
station 1
Work
station 2
Tool
cabinet
PPE MUST BE
WORN AT ALL
TIMES
6
Capture the NEW
layout
Indicate how the
work flows
Scale:
stores
Tool
cabinet
Work
station 3
By Avijit Biswas
Method - standardise
NO REVISION DATE
LOCATION: SHEET……..OF………
DEPT: DATE:
PREPARED BY:
AUTHORISATION:
WORK INSTRUCTION SHEET
OPERATION NO. OPERATION DESCRIPTION
NO MAIN STEPS QSE KEY POINTS EXPLANATION/ EXAMPLES/ DIAGRAMS
P.P.E. JIGS/ TOOLS REQUIRED CHECKS TRAINING COMMENTS
TIME
MEMgr
WP HRS
PEGS REF:
TLTL TL PUM ME
OPERATING DESCRIPTIONNO
Method - standardise
NO REVISION DATE
LOCATION: SHEET……..OF………
DEPT: DATE:
PREPARED BY:
AUTHORISATION:
WORK INSTRUCTION SHEET
OPERATION NO. OPERATION DESCRIPTION
NO MAIN STEPS QSE KEY POINTS EXPLANATION/ EXAMPLES/ DIAGRAMS
P.P.E. JIGS/ TOOLS REQUIRED CHECKS TRAINING COMMENTS
TIME
MEMgr
WP HRS
PEGS REF:
TLTL TL PUM ME
OPERATING DESCRIPTIONNO
By Avijit Biswas
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
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
By Avijit Biswas
Summary
Capture the current state Balance to TAKT & eliminate waste
Update calculations
Balance to TAKT
Reduce Non Value
Added and
eliminate waste
Re-allocate work &
re-balance
Can this
be
improved?
Yes
Complete work
instruction
(standardise) &
implement
No
Balance to TAKT
Reduce Non Value
Added and
eliminate waste
Re-allocate work &
re-balance
Update calculations
Can this be
improved?
Complete work
instruction
(standardise) &
implement
Takt
Total work
content
Line Balance
Ratio
Line Balance
Efficiency
25 hrs
44 hrs
Ops 2
92%
88%
Future State
Takt
Total work
content
Line Balance
Efficiency
Line Balance
Ratio
25 hrs
62 hrs
Current State
Operators 3
69%
83%
Calculate Takt time
Time the process
Draw current state
Line Balance
Calculate Line
Balance Ratio &
Efficiency
Calculate target
manpower
Break down the
work elements
Calculate Takt time
Calculate Line
Balance Ratio &
Efficiency
Time the process
Break down the
work elements
Draw current state
Line Balance
Calculate target
manpower
2
5hrs
1
Summary
Capture the current state Balance to TAKT & eliminate waste
Update calculations
Balance to TAKT
Reduce Non Value
Added and
eliminate waste
Re-allocate work &
re-balance
Can this
be
improved?
Yes
Complete work
instruction
(standardise) &
implement
No
Balance to TAKT
Reduce Non Value
Added and
eliminate waste
Re-allocate work &
re-balance
Update calculations
Can this be
improved?
Complete work
instruction
(standardise) &
implement
Takt
Total work
content
Line Balance
Ratio
Line Balance
Efficiency
25 hrs
44 hrs
Ops 2
92%
88%
Future State
Takt
Total work
content
Line Balance
Efficiency
Line Balance
Ratio
25 hrs
62 hrs
Current State
Operators 3
69%
83%
Calculate Takt time
Time the process
Draw current state
Line Balance
Calculate Line
Balance Ratio &
Efficiency
Calculate target
manpower
Break down the
work elements
Calculate Takt time
Calculate Line
Balance Ratio &
Efficiency
Time the process
Break down the
work elements
Draw current state
Line Balance
Calculate target
manpower
2
5hrs
1
By Avijit Biswas
Line Balancing Problem
A
B
C
4.1mins
D
1.7mins
E
2.7 mins
F
3.3
mins
G
2.6 mins
2.2 mins
3.4 mins
Line Balancing Problem
A
B
C
4.1mins
D
1.7mins
E
2.7 mins
F
3.3
mins
G
2.6 mins
2.2 mins
3.4 mins
By Avijit Biswas
Questions?
•1. What is the bottleneck?
•2. What is maximum production per
hour? 60/4.1=14.63 units
•3. What is efficiency and balance
delay?
•4. How to minimize work stations?
•5. How should they be grouped?
•6. New efficiency?
4.1 minutes
Questions?
•1. What is the bottleneck?
•2. What is maximum production per
hour? 60/4.1=14.63 units
•3. What is efficiency and balance
delay?
•4. How to minimize work stations?
•5. How should they be grouped?
•6. New efficiency?
4.1 minutes
By Avijit Biswas
Calculate efficiency
•A. 73.2%
•B. 56.7%
•C. 69.7%
•D. 79.6%
•E. 81.2%
A
B
C
4.1mins
D
1.7mins
E
2.7 mins
F
3.3
mins
G
2.6 mins
2.2 mins
3.4 mins
Calculate efficiency
•A. 73.2%
•B. 56.7%
•C. 69.7%
•D. 79.6%
•E. 81.2%
A
B
C
4.1mins
D
1.7mins
E
2.7 mins
F
3.3
mins
G
2.6 mins
2.2 mins
3.4 mins
By Avijit Biswas
(2.2+3.4+4.1+2.7+1.7+3.3+2.6)
4.1x7
20
28.7
69.7%
1-69.7%=30.3% Balance Delay
(2.2+3.4+4.1+2.7+1.7+3.3+2.6)
4.1x7
20
28.7
69.7%
1-69.7%=30.3% Balance Delay
By Avijit Biswas
Number of Work Stations
( )
time cycle
times task
TM
å
=
(bottleneck)
20
4.1
= 4.88 work stations
Number of Work Stations
( )
time cycle
times task
TM
å
=
(bottleneck)
20
4.1
= 4.88 work stations
By Avijit Biswas
Line Balancing Solution
A
B
C
4.1
D
1.7
E
2.7
F
3.3
G
2.6
Station 1
Station 2
Station 3
Station 4
2.2
3.4
All under 6 minutes?
(6.0)
(5.6)
(5.8)
4 Stations 20/24=83.3%
Max prod./hour
60/6
10 units/hour
Line Balancing Solution
A
B
C
4.1
D
1.7
E
2.7
F
3.3
G
2.6
Station 1
Station 2
Station 3
Station 4
2.2
3.4
All under 6 minutes?
(6.0)
(5.6)
(5.8)
4 Stations 20/24=83.3%
Max prod./hour
60/6
10 units/hour
By Avijit Biswas
Line Balancing Problem
A
B
C
4.1mins
D
1.7mins
E
2.7 mins
F
3.3
mins
G
2.6 mins
2.2 mins
3.4 mins
5.6
5.0
20/5.6x5 = 20/28 = 71.4%
5 Stations
Max Prod./hour
60/5.6
10.7 units/hour
Line Balancing Problem
A
B
C
4.1mins
D
1.7mins
E
2.7 mins
F
3.3
mins
G
2.6 mins
2.2 mins
3.4 mins
5.6
5.0
20/5.6x5 = 20/28 = 71.4%
5 Stations
Max Prod./hour
60/5.6
10.7 units/hour
By Avijit Biswas
40 secs
59 secs
84 secs
34 secs
56 secs
45 secs
What is the minimum # of work stations?
Round down.
A.3
B.2
C.4
D.5
E.6
40 secs
59 secs
84 secs
34 secs
56 secs
45 secs
What is the minimum # of work stations?
Round down.
A.3
B.2
C.4
D.5
E.6
By Avijit Biswas
( )
timecycle
task timeså
=TM
40+59+84+56+34+45 = 318
318/84 = 3.78 or 3 work stations
What is the efficiency with 6 operators?
()
( )
( )( )
( )100
timecyclestations ofnumber
task times
%Efficency
å
=
318/6 x 84=
318/504 =
63%
( )
timecycle
task timeså
=TM
40+59+84+56+34+45 = 318
318/84 = 3.78 or 3 work stations
What is the efficiency with 6 operators?
()
( )
( )( )
( )100
timecyclestations ofnumber
task times
%Efficency
å
=
318/6 x 84=
318/504 =
63%
By Avijit Biswas
()
( )
( )( )
( )100
timecyclestations ofnumber
task times
%Efficency
å
=
40 secs
59 secs
84 secs
34 secs
56 secs
45 secs
99 secs
118 secs
3 Stations ?
318/3x118
318/354 = 89.8%
101 secs
()
( )
( )( )
( )100
timecyclestations ofnumber
task times
%Efficency
å
=
40 secs
59 secs
84 secs
34 secs
56 secs
45 secs
99 secs
118 secs
3 Stations ?
318/3x118
318/354 = 89.8%
101 secs
By Avijit Biswas
40 secs
59 secs
84 secs
34 secs
56 secs
45 secs
4 Stations?
99 secs
84 secs
56 secs
79 secs
318/4 x 99 =
318/396 =
80.3%
40 secs
59 secs
84 secs
34 secs
56 secs
45 secs
4 Stations?
99 secs
84 secs
56 secs
79 secs
318/4 x 99 =
318/396 =
80.3%
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