Line Balancing is leveling the workload across all processes in a cell or value stream to remove bottlenecks and excess capacity.
Capacity is calculated as
( Number of machines or workers )×( Number of working time )×( Utilization)×( Efficiency ).
Load level
Why need to do LINE BALANCE
Line balancing is a 6-step process.
1. Choose a work area : Identifying
the beginning and end process.
2. Obtain individual cycle time for each work element for calculation:
Record all tasks of an individual operating into Cycle Time Worksheet.
Common attributes of cycle time worksheet
2.1 Product detail(Product group, Style, S/O, Order quantity, Customer name, Shipment date)
2.2 Date of recording
2.3 Recorder name
2.4 Station number
2.5 Operator name each element
2.6 Work
elements name
2.4 Cycle time data
2.5 Total cycle time
3. Add the individual cycle times to obtain the total cycle
time.
4. Create an Current-State operator Balance Chart.
5. Determine the ideal number of operators by dividing cycle time by takt time.
Example Cycle time = 87 seconds ,
Takt time = 42 seconds
Ideal number of operators = 87/42 = 2.07 operators
6. After complete the Current-state operator Balance Chart necessary to meeting for explain the detail to all operators in work area.
Next Step
- Check the actual output all of element if the quantity of output is not in accordance with the targets set must be analyzed the causes and find methods to improve.
- Analysis to determine the Value Adding and Non-Value Adding process Use the Lean tools to eliminate the wastes. For Example MODAPTS
- Re-balance the process again. For
the example, this calculation is as follows: