PRODUCTION LINE
BALANCING
OBJECTIVES
* TO UNDERSTAND WHAT IS LINE BALANCING
* TO KNOW THE BENEFITS AND HOW LINE BALANCING CAN HELP IN
THE OPERATION MANAGEMENT
* TO HAVE AN IDEA ON HOW TO ACHIEVE LINE BALANCING
WHAT IS LINE
BALANCING?
Line balancing is a flow-oriented production strategy for
improving productivity and cost-efficiency in mass production
processes. An optimal time frame is designated for the production
of a particular product. Tasks are then equally distributed among
workers and workstations to ensure that each operation in the line
happens within the specified time frame.
Line balancing is a production strategy that involves balancing
operator and machine time to match the production rate to the Takt
time.
BENEFITS OF LINE
BALANCING
Production line balancing is an excellent model for attaining improved efficiency in the
production process. Some of its benefits are:
•Reduces the amount of idle time in work stations
•Facilitates a streamlined flow of the production process
•It helps to create the right number of workstations and the number of operations to
have in each station.
•Achieves high employee morale and camaraderie by consolidating processes
•Improves the rate of production and the output quality of the produced items
•Maximizes workforce utilization and production capacity
•Reduces wastage
HOW CAN YOU ACHIEVE LINE
BALANCING?
1. Calculate Takt time
Since the goal of line balancing is to match the production rate to
Takt time, being aware of your Takt time is essential. Takt time
cannot be measured with a stopwatch. It needs to be
calculated with a formula.
Takt time = Available Working time Per shift / Rate of customer
demand per shift
TAKT TIME
It describe the required product assembly duration that is needed to
match the demand.
2. PERFORM TIME
STUDIES
The goal of time studies is to establish the time required to
complete each task along a production line. In other words, you
want to find out how long employees and machines spend on each
part of a process.
3. IDENTIFY
BOTTLENECKS AND
EXCESS CAPACITY
When it comes time to analyze the data from your time studies,
notice which parts of the process are taking longer than Takt time.
Exceeding Takt time means late deliveries, high shipping costs or
unhappy customers. Also, notice which parts are taking less than
Takt time. There is excess capacity in those places.
4. REALLOCATE
RESOURCES
Start by considering task precedence, which is the sequence in
which tasks must be carried out. For example, if a step requires a
certain part, you need to make sure that part is completed before
reaching that step.
5. MAKE OTHER
IMPROVEMENTS
The analysis of the quantitative data on your lines will surely reveal
other opportunities for improvement that could improve the
balance of your lines.
To implement process improvement, you can manipulate three
parameters: operator time, machine time, and setup time.
TO SUM IT UP!
Line balancing is an optimization problem with significant industrial
importance. By improving the efficiency of their lines,
manufacturers can reduce the wastes of Lean manufacturing and
unlock more value.
REFERENCES
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