SUMMARY

<Formula of Daily Output>

Daily Output =

Daily Work Hours Number of Operators

Organization Efficiency
Net (Basic) Total Processing Time (1 Allowance Rate)
<Time Study>
- Point 1) Take the cycle time (Pick to pick)
2) Do not include allowance time
<Operation Analysis (Allowance rate)>
- Point 1) Judge what things operator is doing at the moment.
2) Formula
Operation Rate = Operation Number / Total Number x 100(%)
Allowance Rate = Allowance Number / Operation Number x 100(%)
<Make Pitch Diagram (To check actual line balance)>
- Contents 1) Process Chart (Process time)
2) Number of Operators
- Procedure 1) Calculate average time.
If 2 or more workers do same operation, use Harmonic mean.

2
2AB
1
For 2 workers:
or 1

AB
A B
For 3 workers:

3
3ABC
1 1
or 1

AB BC CA
A B C

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SUMMARY

2) Calculate total process time.(Total time of average time)

3) Calculate B.P.T. (Basic Pitch Time)
Basic Pitch Time =

Net (Basic) Total Processing Time

Number of Operators

4) Calculate U.C.L. (Upper Control Limit) & L.C.L. (Lower Control Limit)
U.C.L. (Upper Control Limit) =

B.P.T.
Target Organization Efficiency(0.85)

L.C.L. (Lower Control Limit) = (2 B.P.T.) Upper Control Limit

5) Draw Pitch Diagram

6) Find Bottleneck Process & calculate Organization Efficiency.

Organization Efficiency

Pitch Time
x 100(%)
Bottleneck Process Time

7) Take the immediate action.

-

Re-distribute the work to maintain balance

Do Motion-Study to reduce the processing time

Do action to reduce Allowance rate of Bottleneck process

Help bottle neck process by another operator for maintain balance

etc.

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