Line Balancing Ppt

8/9/2019 Line Balancing Ppt

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Line balancing

© SOFT Student Handouts,

By, Sunil Talekar, Faculty, SOFT-Pune



What is line in apparel anu!acturing"

Line# an assebly line coposed o! se$eral %orkstations, at %hich speci&c operations areper!ored' To %ork e(ecti$ely, %ith no %ork pile-

ups bet%een stations, the line ust bebalanced

,e'g' %ork ust get through each %orkstation inroughly the sae aount o! tie'



hat is Line Planning"

Line planning is scheduling and allocating o! orders to productionlines according to product setting )product is being ade in the line*

and due dates o! production copletion' + line plan de&nes %hen astyle is going to be loaded to the line, ho% any pieces to beepected )target* !ro the line and %hen order to be copleted' Foreaple, please re!er to the !ollo%ing Table-, %here a siple lineplanning has been sho%n in spread sheet'

.uring booking orders or allocating orders to the production line,planners ust check %hat is running on the line and ho% any daysit %ill take to coplete the /unning style'

Bene&t o! Line planning# 0t helps production anager as %ell as linesuper$isor %ith in!oration such as %hat is the daily productiontarget !or line' They set their line )achines and anpo%er*accordingly' Line plan also pro$ides in!oration such as ho% anydays style %ould run, %hat is the net style going to be loaded"



Line plan

Line 1 Line 2 Total

DateDailyProd.

CummProd.

DailyProd.

CummProd.

DailyProd.

-.ecloading 1234+,5ty -3666 pieces 366 266 366

2-.ec 266 266 366 766 7663-.ec 276 476 366 866 776

4-.ec 466 876 266 2666 966

7-.ec 466 276loading 1Polo ,

5ty -766 pieces 4669-.ec 466 976 6 6 466:-.ec 466 2676 66 66 7668-.ec 466 2476 366 466 :66;-.ec 466 2876 376 :76 :76

6-.ec 76 3666 376 66 766

-.ecloading 1432<,5ty -7766 pieces 466 766 466

2-.ec 66 66loading 1=<47,5ty -4766 pieces 66

3-.ec 276 376 266 266 476

4-.ec 766 876 276 476 :76

7-.ec 766 376 466 876 ;66

9-.ec 766 876 466 276 ;66

:-.ec 766 2376 466 976 ;66

8-.ec 766 2876 466 2676 ;66

;-.ec 766 3376 466 2476 ;66

26-.ec 766 3876 466 2876 ;66

2-.ec 766 4376 466 3276 ;66

22-.ec 766 4876 466 3976 ;66

23-.ec 76 7666 466 4676 776

Daily Prod. ? .aily production or line outputCumm Prod' ? @uulati$e production o! the style till date



L0A B+L+A@0AC

L0A B+L+A@0AC )Process OrganiDation* The Line Balancing is E

to design a sooth production o% by allotting processes to%orkers so as to allo% each %orker to coplete the allotted

%orkload %ithin an e$en tie G

L0A B+L+A@0AC )Process OrganiDation* 0t is a syste %here you

eet the production epectations and you can &nd the saeaount o! %ork in process in e$ery operation at any point in theday'



WH= L0A B+L+A@0ACI the ain Job in line balancing is to eliinate orreduce %ip )%ork in process* at bottleneck operations'

I keeps in$entory costs lo%, resulting in higher netincoe

I allo%s operator to %ork all day long gi$ing anopportunity to earn ore oney and increases hisKher%ork e ciency

I keeps the prices lo% %hich turns into repeat sales

I eans better production planning



There are 3 rules for

balancing(1) HAVE AT LEAST ½ HOUR OFWIP FOR EACH OPERATION

(2) SOLVE PROBLEMS BEFORE

THEY BECOME ANY LARGER(3) MEET PRODUCTION GOALS BY

KEEPING EVERY OPERATOR

WORKING AT THEIR MAXIMUMCAPACITY



L0A B+L+A@0AC TOOLS

ProductionsheetsDaily productionreport

The inventorylevels by operation

Production

boardsStop atch

Calculator



PROCESS OF LINE BALANCING

• Determine the tasks to be performed

• Determine the order

• Formuate the pre!eden!e dia"ram

• Estimate the time

• Ca!uate !#!e time

• Ca!uate minimum $orkstations

• %se the heuristi!s to assi"n tasks



&O' CAN 'E (ANAGE 'IP)

(1) Produc!o" #$%""!"&

(2) Tr!'( co"ro$

(3) Produc!o" Bu!$d)u#

(4) L!"* B%$%"c!"&

(5) Cu F$o+ Co"ro$



Line balancing in apparel anu!acturing

STPS TO + B+L+A@. L0A

ST!P 1. C"LC#L"T$%& %' T(! L")%**!+#$*!,!&TS "&D C"P"C$T- ST#D-

TH /5M0/NAT OF WO/</ .PA.S MPOA TH P/OB+BL FF0@0A@=OF TH L0A SL@T. +A. P/@AT+C OF T0N TH= WO/<'

List don all operationsith operator name as peroperation seuence

Chec/ cycle time for eachoperation for 0ve

consecutive cyclesith average cycle timecalculate hourly capacityof the operatorsith the help of the hourlycapacity calculate the labour

reuirement




ST!P 2. %P!*"T$%&"L )*!"D%&"&D S!TT$&4 T(! T"*4!T

B ' • 1 i t h t h e c a p a c i t y d a t a s e t t a r g e t o u t p u t p e r h o u r f r o m o n e l i n e .

@ ' • T a r g e t p e r h o u r 5 T o t a l n o o f o p e r a t o r s 6 7 8 9 g a r m e n t S " ,

. ' • C u r r e n t h o u r l y o p e r a t o r p r o d u c t i o n r e p o r t i s a n a l y : e d

ST"&D"*D"LL%!D,$&#T!S %'

!"C( %P!*"T$%&

;+'




ST!P 3< T"*4!T S!TT$&4

ith the above step 1 = 2 data setyour target output per hour from oneline.

4enerally it is calculated usingfolloing formula >Target per hour5Total no of operators 6 78 9garmentS",?.

Chec/ current hourly operatorproduction report. Dra a straight lineith target output data on the linegraph.



A The time at hich the longest time isreuired is called B)ottlenec/ ProcessA The state of line organi:ation should beevaluated as B%rgani:ation !ciency

A Pitch Time provides average time allottedto each or/er. A #sing the pitch time and )ottlenec/Process Time.

ST!P E. $D!&T$'$C"T$%& %' )%TTL!&!C "*!"S

P!c, T!'* #ro-!d*( %-*r%&* !'* %$$o*d o *%c, +or.*r

T,* !'* % +,!c, ,* $o"&*( !'* !( r*/u!r*d !( c%$$*d 0bottleneck Process”. T,*(%* o1 $!"* or&%"!2%!o" (,ou$d 3* *-%$u%*d %( “Organization Efficiency” U(!"&

,* #!c, !'* %"d Bo$*"*c. Proc*(( T!'*4

Pitch i!e

OrganiDation ciency )* QQQQQQQQQQQ 66

Bottleneck Process Tie

66 5 666666 X 788

46 :'4 9For ,* %1or*'*"!o"*d c%(* (ud:;



*educe cycle time using or/ aids and attachments

$mprove or/station layout and improve methods

"dd more operators at bottlenec/ operations. "lso comparethe costFbene0ts of putting additional machine into the line.

ShuGe operators. %perations that have lo or/ content use

lo performer hile or/ content is higher use highperformers.

Club operations here possible. 4ive the operator anotheroperation ith less or/ content considering machine type

and seing thread colors.

Nethods o! eliinating bottlenecks !ro the line

ST!PE. !L$,$&"T$%& %' )%TTL!&!CS '*%, T(! L$&!




F/ON 0NB+L+A@. L0A''

To Balanced line

+ll in all

Line Balancing Ppt

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