Adithy Kottangal Adithy Kottangal
Jan 21, 2015
Adithy KottangalAdithy Kottangal
IntroductionIntroduction
What is Line Balancing?What is Line Balancing?
Line Balancing is the technique of Line Balancing is the technique of planning sufficient work load to each planning sufficient work load to each operator to achieve required output.operator to achieve required output.
Line Balancing includesLine Balancing includes
Everyone is doing the same amount of Everyone is doing the same amount of wok.wok.
Doing the same amount of work to Doing the same amount of work to customer requirementcustomer requirement
Variation is smoothedVariation is smoothed No one over burdenedNo one over burdened No one waitingNo one waiting Everyone working together in balanced Everyone working together in balanced
fashion fashion
Introduction : What is Line Introduction : What is Line Balancing?Balancing?
Introduction : What is Line Introduction : What is Line Balancing?Balancing?
When is the Line Balancing When is the Line Balancing required?required?
Before starting a new styleBefore starting a new style While the style is being producedWhile the style is being produced
Everyday when the production starts or Everyday when the production starts or more than one time a day, it depends on more than one time a day, it depends on the situation the situation
Line Balancing depends on;Line Balancing depends on;
Performance of the individualsPerformance of the individuals Work in progressWork in progress AbsenteeismAbsenteeism Labour turnoverLabour turnover Management efficiencyManagement efficiency
AdvantagesAdvantages
Line Balancing is an effective tool to improve the Line Balancing is an effective tool to improve the through put of assembly line while reducing man through put of assembly line while reducing man power requirements and costspower requirements and costs
It results in less work in processIt results in less work in process Assembly line balancing ensures:Assembly line balancing ensures:
1.1. The minimization of the number of work The minimization of the number of work stationsstations
2.2. The minimization of cycle timeThe minimization of cycle time
3.3. The maximization of work load The maximization of work load smoothnesssmoothness
4.4. The maximization of work relatednessThe maximization of work relatedness
ProblemsProblems When assigning different tasks to When assigning different tasks to
individual workstations sum of task time individual workstations sum of task time at any stations should not exceed the at any stations should not exceed the station time.station time.
Potential bottlenecks and work imbalancePotential bottlenecks and work imbalance Machinery failureMachinery failure Slow operators and absenteeism may Slow operators and absenteeism may
interrupt the work flowinterrupt the work flow The change of operator efficiency during The change of operator efficiency during
real time production is the main reason real time production is the main reason that causes production line imbalancethat causes production line imbalance
Solution for ProblemsSolution for Problems
Cross train operators to perform Cross train operators to perform more than one operationmore than one operation
Substitute machines must readily Substitute machines must readily available for immediate replacement available for immediate replacement if equipment breaks downif equipment breaks down
Reroute work, shift personal or Reroute work, shift personal or reschedule to avoid delaysreschedule to avoid delays
EngineeringEngineering
Operation bulletin and machine Operation bulletin and machine specificationsspecifications
o Article details Article details o No of operations involvedNo of operations involvedo Types of machines usedTypes of machines used
Dividing the line in to two partsDividing the line in to two partso Preparation areaPreparation area
Small parts attachment Eg : Zipper to Small parts attachment Eg : Zipper to flyfly
o Assembling areaAssembling area
Assembling the garment Eg : Planning Assembling the garment Eg : Planning attachmentattachment
SMVSMV
Visually absorbing the time taken by Visually absorbing the time taken by the operator for the specific taskthe operator for the specific task
Repeating the exercise for number Repeating the exercise for number of time of time
Standardizing the value Standardizing the value Calculating the SMV of garmentCalculating the SMV of garment Forecasting the productionForecasting the production Implementing on the lineImplementing on the line
Calculating number of operators Calculating number of operators required for each operationrequired for each operationo Balance the line by adjusting the Balance the line by adjusting the
number of operators tact time (TOPS)number of operators tact time (TOPS) EfficiencyEfficiency
o Production @100%Production @100%o Production at present efficiencyProduction at present efficiencyo Implement the betterment on the lineImplement the betterment on the line
Example Example Coin pocket hem takes 0.16 minutes and Coin pocket hem takes 0.16 minutes and
requires one machine with the target of requires one machine with the target of 375 pieces, the next operations in the 375 pieces, the next operations in the preparation area is coin pocket preparation area is coin pocket attachment on the facing takes 0.35 attachment on the facing takes 0.35 minutes with the target of 171 pieces minutes with the target of 171 pieces @100% efficiency. Working time is 8 @100% efficiency. Working time is 8 hours. According to TOPS, operator hours. According to TOPS, operator required for the first operation would be required for the first operation would be 0.68=1 but the operator required for 0.68=1 but the operator required for the second operations would be1.5=2.the second operations would be1.5=2.