2. 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
3. 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
6. 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,
7. 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
8. 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
9. 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
10. 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
11. 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
12. By Avijit Biswas
Standardise
Highlight key
information
Operation
sequence
From:
To:
Cell/ Area
Description: Part No.
Quality check Safety precaution Std in process stock
Qty of SIPS Takt Time Cycle time
Standard work layout
Name / position Date Name / position Date Name / 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
13. 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 Q S E KEY POINTS EXPLANATION/ EXAMPLES/ DIAGRAMS
P.P.E. JIGS/ TOOLS REQUIRED CHECKS TRAINING COMMENTS
TIME
MEPUM
WP HRS
PEGS REF:
TL TL TL PUM ME
OPERATING DESCRIPTIONNO
As per PEGS requirement
14. By Avijit Biswas
The benefits of the pre-requisites
Takt time
Standard Operations
What do you think
are the benefits?
15. 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
16. 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
17. 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
18. 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
10 3 4
1
10 4 2
15
2
0 0 0
1 Fit bracket A
Walk to bench
Inspect
1
Machine 2 10 5
TAKT
18 of 43
19. 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
20. 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
21. 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
22. 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
23. By Avijit Biswas
Method – capture current stateLine 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
25. 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 WalkISSUER¨ COORDINATOR¨ MGR¨ ISSUER Auto Waiting
TIME OPERATION TIMEOPERATION NAME
STANDARDISED WORK
COMBINATION TABLE
TOTAL
10 3 4
1
10 4 2
15
2
0 0 01 Fit bracket A
Walk to bench
Inspect
1Machine
2 10 5
TAKT
26. By Avijit Biswas
Method – balance toTAKT
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
27. 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 !!
28. 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
29. 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 MANUAL AUTO WAIT WALK
KEY:
Manual Walk
ISSUER¨ COORDINATOR¨ MGR¨ ISSUER Auto Waiting
TIME
OPERATION TIMEOPERATION NAME
STANDARDISED WORK
COMBINATION TABLE
TOTAL
10 3 4
1
10 4 2
15
2
0 0 0
1 Fit bracket A
Walk to bench
Inspect
1
Machine 2 10 5
TAKT
So, identify the category of work on the
standard work combination table
29 of 43
30. 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…
31. 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
32. 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
33. 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
34. 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%
35. 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
36. By Avijit Biswas
Method - standardise
Highlight key
information
Operation
sequence
From:
To:
Cell/ Area
Description: Part No.
Quality check Safety precaution Std in process stock
Qty of SIPS Takt Time Cycle time
Standard work layout
Name / position Date Name / position Date Name / 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
37. 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 Q S E KEY POINTS EXPLANATION/ EXAMPLES/ DIAGRAMS
P.P.E. JIGS/ TOOLS REQUIRED CHECKS TRAINING COMMENTS
TIME
MEMgr
WP HRS
PEGS REF:
TL TL TL PUM ME
OPERATING DESCRIPTIONNO
38. 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
39. 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
40. 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
41. 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
42. 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
44. By Avijit Biswas
Number of Work Stations
( )
timecycle
timestask
TM ∑=
(bottleneck)
20
4.1
= 4.88 work stations
45. 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
46. 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
47. 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
48. By Avijit Biswas
( )
timecycle
task times∑=TM
40+59+84+56+34+45 = 318
318/84 = 3.78 or 3 work stations
What is the efficiency with 6 operators?
( )
( )
( )( )
( )100
timecyclestationsofnumber
task times
%Efficency
∑=
318/6 x 84=
318/504 =
63%
Ask the audience what they know about line balancing
Jot down their answers on a flip chart
When you have exhausted the responses go through this slide (the points will appear one at a time)
This slide is meant to be a bit of fun!
It simply shows a couple of examples of when a line is NOT balanced – highlighting the OVERBURDEN by some operators and the WAITING of others
You can also point out how INVENTORY is being built up.
The top drawing shows how LARGE BATCH QUANTITIES create INVENTORY and WAITING
The bottom drawing demonstrates how the guy in the middle has obviously got a longer process than the other two therefore creating an IMBALANCE which then creates WAITING and INVENTORY. The chap in front of him is also OVERPRODUCING.
Here the example shows what a line should look like when it is balanced.
This means that all of the operations take near enough the same amount of time.
The product can then flow through the line ‘one-piece-at-time’ so that each process receives a consistent supply of product right through to the final customer
Here, if quality issues are found then the line has to stop and DEAL WITH THEM! – In the previous example quality issues can be hidden due to the INVENTORY in the system.
To avoid affecting the customer with a line stop a ‘standard-in-process-stock’ can be kept between the last operation and the customer. This is a controlled level of stock that compensates for variations in demand / production.
At the end of the day, the production needs to be as stable and consistent as possible – like a drum beat!
This is an example of a line balance chart
The Line balancing board is a management tool that visually represents the elements of standardised work in a clear and easy to understand way.
The line balance chart serves many purposes ranging from being a very simple “snapshot\layout” of a process to a much more detailed planning and organisation tool . However all it’s functions are used in conjunction with setting up and maintaining manufacturing processes
This is a simple example.
Here we have four processes, each with different process times (depicted below in graph form).
As you can see, operation 1 has the shortest time and operator 2 has the longest. Therefore, operator 2 is the CONSTRAINT.
This means that operator 2 will have to do more work than the others meaning that he is OVERBURDENED. Since operator 1 has the shortest time it means that either he sits and WAITS for operator 2 or he OVERPRODUCES to fill his time. This creates the INVENTORY that you can see.
The other following operations tend to WAIT for Operator 2 also.
If Operator 1 does OVERPRODUCE, then this tends to create the other WASTES in the system. The wastes can be identified into 7 categories…..
If we were to re-allocate some of the work from operator 2 onto lets say operator 2 then we can see how this can make the line more BALANCED.
This reduces VARIATION in the process,
Minimises the 7 wastes
Avoids overburden
And promotes one-piece-flow.
Once again , all of these attributes help achieve a stable work environment in which variations can be detected quickly and dealt with. The customer or final in-process-stock also receives a consistent supply of product.
Due to the low level of inventory in the system, if the customer changes his order drastically the system allows you to be flexible as you do not have to scrap large amounts of stock.
Rather than working in batches, this system also encourages you to change over more frequently. At first this may be an issue as the process may not be set up for this. However, this is where change over reduction activities can be used
These are the two pre-requisites to line balancing.
Takt time is simply the ‘time available to produce components in a year’ divided by the ‘customer demand’ giving you a drum beat of customer demand.
I f we know how many products we need to produce at regular intervals then we can balance production to meet this. Ensuring that we always meet our customer requirements.
It also enables us to calculate the required level of manning for production also.
STANDARDISE – what we mean by this is STANDARDISING the operations so that we have a base line on how the job should be completed. This enables better management of the process and problems or variation from the process can be determined more effectively. This is vitally important as one-piece-flow demands that you are able to resolve issues quickly. Otherwise you will stop the customer ultimately!!
(READ SLIDE)
If you were required to produce 10 units a month, then a in a 20 day month you would simply need to produce 1 unit every 2 days.
This also enables you to visually manage your production more effectively. If you know that you are to produce a component every two days then you know that after 1 day you should have completed 50% of that component, and at lunch time you should be 25% of the way into completing the first part. If for any reason this is not the case then production management need to understand why that is the case and react accordingly (using problem solving techniques and escalating the issue if necessary).
Visibly displaying this situation enables management to closely manage production more effectively. This enables adherence to TAKT (customer requirement) and makes sure that issues are resolved as they occur. In this way the issues that occurred frequently in the past will gradually decline in there occurence creating a more stable environment.
In this stable environment people can spend more time focusing on continuous improvement of the process and resource can be freed up for other activities.
Standard formats are popular tools for detailing the way that process should be run or managed.
Here is an example of a ‘Standard work layout’ document which would be used to detail:
How the cell should be layed out (position of machines/ people / Stock locations
How the material should flow through the area.
Highlighting Health and safety information.
This document should be signed off by the team leaders of the area and the local area manager. It should be visibly displayed in the area for all to see (along with other standard documents or on a visual management board.
This standard is really the ‘manufacturing way’
If the process is detailed in this way and worked to then the process becomes more manageable and is a ‘stake in the ground’ for improvements to made
Ask the audience why THEY think TAKT and STANDARD OPERATIONS are important pre-requisites.
Jot their answers on a flip chart
Discuss their responses (10 minutes)
If the audience has not been able to come up with all of the answers then read through this slide as a back up.
So now we are moving into the actual method of line balancing. The next few slides detail an example which we are going to work through.
The first thing to do do is to calculate TAKT.
Read through slide
You will notice at the bottom right of the page that we are going to keep a record of some of the key information from each slides.
This is the best way for capturing the data
Waste and NVA can be identified more easily and can allow the team to spot things that they previously didn’t realise occurred.
Videoing a process is more difficult than you think. You must concentrate on capturing the process (not the man). Sometimes the operator may be unavoidable, in these cases it may be prudent not to capture his mugshot!!
After videoing the process the video must be reviewed WITH THE TEAM.
Another standard document that should be used at this stage is called a ‘STANDARD WORK COMBINATION TABLE (SWCT). This document is used for detailing each of the process elements that can be seen from the video. It is then used to highlight VA / NVA and waste and detail the time. The TAKT can then be seen clearly and the operations can be sketched out along the time frame.
This document is the record of how the job is actually carried out and can be used at a later stage for balancing the work out between operators.
Use some red and green lego to demonstrate this
It may be a good idea to use a hard copy of the table so that the attendees can fill it out as you go
VSM can be used to identify the area to be studied
A cross functional group with varying levels of experience is preferred
Write on post-it notes the process name and the estimated time.
Try to gain as accurate a picture as possible
The post its can be stuck onto the brown paper to create ‘little towers’ of process times.
The TAKT line is also drawn on at this stage
The target manpower is calculated by adding up the total work content of the job and dividing it by the TAKT.
This will give you something to aim for as it will tell you how the process could (in terms of the manpower required) run without any efficiency losses in a perfectly balanced state.
If the figure comes out as 2.48 (as in the example) then you will have to round the figure up to 3 and except that there will be some spare capacity in the cell. If however, the it comes out as 2.02 or 2.1 then you can justify only using 2 on the basis that the 0.1 could be reduced through continuous improvement.
This tells you that without making any improvements in the process, the customer demand can be met and a efficiency of 83% can be achieved
The objective now is to balance all of the timed elements of work to TAKT.
At this point give out the SWCT hand out
This is the method that can be used without video equipment.
It is based on estimates but is very visual and imbalances can be noticed very easily.
As the video is being reviewed it is important to get the operators to identify what elements of work are Value added, Non-value added, and Waste.
Read through the descriptions of each on the slide.
Value added – example – when a drill is actually cutting metal (not moving into the work piece)
Non-value added – example – inspection, putting a part in a jig,
Waste – T.I.M.W.O.O.D - The 7 wastes are : Transportation, Inventory, Motion, Waiting, Overproduction, Over-processing, defects
Read the slide
Line balancing is about identifying and eliminating waste from the process and balancing out the remaining work in the most efficient way. Big improvements can be made without even looking at the cycle time of the machine or process. Once the wastes in the system have been minimised then more benefit will be yielded from attacking the VA work. If this doesn’t happen the effects will be hidden, lost or have minimal effect.
Highlight each of the eliminate in either green or red to indicate whether the work is VA or NVA or WASTE (some formats have columns for VA,NVA,WASTE)
Read the slide
This standard is really the ‘manufacturing way’ If the process is detailed in this way and worked to then the process becomes more manageable and is a ‘stake in the ground’ for improvements to made
Constructing a line balance chart on a white board is the best way for making it visible.
Magnetic strips can be cut to represent the NVA and the VA elements.
The strips can then be redistributed - simulating the possible effect of a change in resource or Takt time.