LINE BALANCING

         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: