MANUFACTURING

EXCELLENCE
MODULE 2
LINE BALANCING
OBJECTIVES
 Understand what line balance is.
 Identify when line balance needs to be done
 Identify what information is required to do line
balance
 Learn 2 different ways to do line balancing
 Identify when to use each way of balancing
 DEFINITION

Line balancing is the process of assign the

workload in each operation in a way that
each operation is done in almost the
same amount of time.

Let’s see a short video

MODULE 1 :
INTRODUCTION : WHAT IS LINE BALANCING?

 Everyone is doing the same amount of work

 Doing the same amount of work to customer
requirement
What is Line
 No one overburdened balancing?

 Variation is ‘smoothed’
 No one waiting
 Everyone working together in a BALANCED
fashion

2017 ME TRANING | CHAPER

01 – IE BASICS

5
LINE BALANCING PROCESS

Build Sewer Database:

- After finished sewing of the 1st style, IE updates highest potential
efficiency of the sewer on the Sewer Database.

Pre-set Line Balance :

- IE use the Sewer Database for initial line balancing and sewing line layout
- IE continuously monitor actual efficiency of the sewer and update the data

Line balancing study in 2nd days after changeover :

• IE conduct cycle study, Create LB Graph compared with target LB rate
• Provide recommendation to supervisor, and discuss with supervisor on the
improvement solution

Review the line balance 5th day after changeover :

• Analysis the reason if the line did not hit target
• IE continuously monitor actual efficiency of the sewer and update the data

2017 ME TRANING | CHAPER 01 – IE BASICS 6

 Why is important to do it
 Increase Efficiency
 Reduce waiting time
 Reduce WIP
 Reduce transportation
 Reduce production cost
 Reduce lead-time
 Improve the man-hours allocation
 Identify machinery requirements at early stage.
Bottleneck: Excess
slowest operation
and results as
capacity:
material waiting – fastest operation,
inventory results in operator
waiting.

 Work In Progress: *Hides the problem

No possible to identify bottleneck, team leader

will not do line balancing.
Quality cannot be controlled.
Poor utilization.
 When do you need to do line balance?

 Start a new style

 Increase production/capacity
 Increase efficiency

 High inventory in an operation (s)

 Absenteeism
Who has to do the line
balancing?
 LINE BALANCING
who should do it?
IE
 Keep skill matrix updated
 For New Styles: prepare Initial Line balance and machine
requirement
 Evaluate the productivity of the line balance (provided by
line leader)
 Set up and follow up re-training plan
 Follow up low efficiency operators per operation
 Improve and standardize methods
 LINE BALANCING
who should do it?
LINE LEADER
 Make the line balance
 For RUNNING STYLES :Submit the line balance to the IE and
Production Sup/ Mgr
 Implement line balance
 Support the line to reach efficiency target
 Control WIP and re-balance when necessary
 LINE BALANCING:

1. TAKT TIME
2. CYCLE TIME
 LINE BALANCING

1. TAKT TIME
TAKT TIME

The heartbeat of production.

It is the pulse that reflects how
we will fill the customer’s
requirements
 TAKT TIME
LINE BALANCING
What information do you
need to do line balancing:
 TAKT TIME
LINE BALANCING
Average cycle time per operation

Target per day for the line :

required by planning
TAKT TIME
1. CALCULATE YOUR DEMAND
2. CALCULATE YOUR AVAILABLE TIME
EXCLUDING YOUR BREAKS &
MEETING TIMES
3. CALCULATE YOUR TAKT TIME =
AVAILABLE TIME / DEMAND
Available Time
Total daily required quantity
4. COMPARE YOUR CYCLE TIME AGAINST
TAKT TIME USING BAR CHART
Line Balancing: Basic Tee

Takt time: 18sec Operators : 8

Where is the CONSTRAINT?
Determine the Optimal Loading:

Sum all cycle times

# of Operators
Takt Time

(9 + 20 + 20 + 2 + 15 + 5 + 5 + 12 + 6) ÷ 18 sec/pc (TT)

Or

89.5 ÷ 18 = 4.5 (or 5 operators)

The design of the production area must accommodate

the multi tasking you have available over time
Redistribute the work in the most
“waste-free” manner
Each Operator’s
cycle time must be
equal to or close to
takt time. Kaizen
the operations
which are far from
takt time or shows
to create potential
bottleneck
LINE BALANCING PROCESS- TAKT TIME
Redistribute the work in the most “waste-free” manner

 Identify bottleneck operation

 Rearrange bottleneck operation: Balance the workload by
share/move elements of the method
 Improve the bottleneck operation to reduce it’s time value.
(kaizen)

 Improve handling & fabricate machine folders & attachments

 Reduce cycle time by additional/shared operator
 Separate & Eliminate operation elements
 LINE BALANCING
TAKT TIME
BENEFITS

 Set up that pace of the output

 Production pace according to customer demand.
 Balance the workload among all operators by shifting
responsibilities: combine or eliminate operations.
 LINE BALANCING

2. CYCLE TIME
 CYCLE TIME LINE
BALANCING

What information do you

need to do line balancing:
 SKILL MATRIX
 Keep Skill records by operators with their efficiency on
different operations
 Include all the operators in the team/line
 Needs to be regularly updated
OVL: Lock
OVL:jo OVL: OVL OVL:
join collar OVL OVL
in Join Join attache
upper Attach and Join Join
upper lower topstitc upper d
and ed Join back, Join lower back Staysti
and insert h back and 3 sleeve
lower back Should and should bck joke tch
lower and neck lower stripes insert
sleeve neck ers attache er and and collar
sleeve back tape sleeve to
s and tape d rolled rolled
s pannel w/3 should
sidese adicom tape tape
slanted slanted stripes er
ams label
Ha 27% 96% 77%
Thoa 71% 83%
Hang 9% 90% 49%
Tay 74%
Nga 20% 15% 44% 73%
Hieu 91%
Thuy 68%
 OPERATION BREAKDOWN
 SMV/ GSD BREAKDOWN
 ELIMINATE NVA
 REQUIRED MACHINE TYPE PER OPERATION
OPERATION LIST
FW1306LHMX001+FW130 Revi Product Sketch

6LHMX001AU+FW13LHM se
Style X006P No.
21/2/
Type T-Shirt Date 56
Custo K.
mer Adidas Football By NYM
Sampl
e 14.80
Stage Production SAM 7
SMV Press
Machi Attachme
Part O Description 100 ne Needle ure Problem Solution
nt
p. % foot
Loa Loading
1 0.478 MAN
ding Chuẩn bị
Overlock join upper and
Slee
2 lower sleeve slanted 0.754 OL2
ve
VS tay trên& dưới
Coll Join front to back collar &
ar 3 lock Staystitch 0.771 SNC
Prep Nối cổ trước&sau+lược
Bac Overlock join back yoke
 PRODUCTION PLAN
 PROVIDED BY PLANNING

PLANNED START
STYLE (Ma) PLANNED START NUMBER OF
LINE # TARGET CHANGEOVER END SEW
TYPE DECORATION PLAN QTY TARGET SEWING PRODUCTION
( Chuyen) (PLAN AS OF SAM
(Loai) (Trang trí) (So luong) EFF
QTY/DAY PREPARATION
(Ngay bat
(Ngay ket
DAYS
PHASE 2 27/7/2013 ) Định (Ngay chuan bi thuc)
(%) dau may) (Số ngày Sx)
mức/ngày CO)

3 S1406GPSCM500 38.2 PANT HE2 5,097 50% 212 8/20/2013 8/30/2013 9/26/2013 24

FW1306LHMX003-
3 8.93 short he3 2,950 55% 738 9/16/2013 9/26/2013 9/30/2013 4
SHORT

SHOR
3 L3000109 15.1 HE1,EM3 700 55% 233 9/20/2013 9/30/2013 10/2/2013 3
T

SHOR
3 FW1306LHMX002 11 HE1,EM2 234 30% 117 9/22/2013 10/2/2013 10/3/2013 2
T

SHOR HE2,EM1,B
3 LM13KCM202 13.1 134 30% 67 9/23/2013 10/3/2013 10/4/2013 2
T ONDING1
 What information do you need
to do line balancing:

 Skill matrix : efficiency/cycle time & historic data

per operator

 SMV per operation: standard minutes

value per operation.

 Machine type per operation

 Target per day for the line

CYCLE TIME- LINE BALANCING
Step by Step:
7. When finish the
6. Adjust the balance if
1. List down all the analysis of all
more capacity is
operations breakdown in operations: calculate the
required or transfer
sequence efficiency target of the
available time
final line balance

2. Identify how many

5. Compare total actual 8. Identify the operators
pieces per hour/day is
capacity in the operation that still have available
required by planning:
against target time: re-training plan
target

3. Identify/assign the 4. Calculate the capacity

operators for each per hour of each
operation operator per operation

Let’s go one by one

CYCLE TIME-LINE BALANCING
Step by Step:
1

List down all the

operations
breakdown in
sequence
CYCLE TIME- LINE BALANCING
Step by Step:

SEQUENCE OF OPERATION BREAKDOWN AND SMV/GSD

Sequence Operation SMV
1 Loading T-shirt Short Sleeve 0.5453
2 4OL Join Shouder 0.5077
3 1L Join and mark neck rib and prestitch 0.4219
4 4OL Attach neck Rib 0.9255
5 OPR Cut back neck excess 0.2661
6 1L Attach back neck tape 0.4824
7 1L Join Label 4 Ply STD 0.4249
8 1L Attach label 3x 0.5074
9 1C Topstitch front Neck 0.3906
10 1L Topstitch back neck tape 0.3346
11 Topstitch fold edge sleeve 1.1506
12 Bartack 1cm at edge sleeve 2x 0.2401
13 2CO Topstitch bottom hemming 0.6340
14 Bartack 1cm at bottom hemming 0.1928
15 4OL Attach sleeve 2x + marking body 1.1030
16 4OL Join sideseam 0.9193
CYCLE LINE BALANCING
Step by Step:
1. List down all the
operations
breakdown in
sequence

2. Identify how
many pieces per
hour/day is required
by planning: target
PLANNING REQUIREMENT

Product t-shirt
STYLE AA99BB88
Total quantity required 16,000
# days of production 25
pcs per day 640
pcs per hr 80
CYCLE LINE BALANCING
Step by Step:
1. List down all the
operations
breakdown in
sequence

2. Identify how
3. Identify/assign
many pieces per
the operators for
hour/day is required
each operation
by planning: target
Seq Operation Operator Seq Operation Operator
1 Loading T-shirt Short Sleeve Kevin 8 1L Attach label 3x Grace
Paul 9 1C Topstitch front Neck Jazmine
2 4OL Join Shouder John 10 1L Topstitch back neck tape Kim
Sharon Joan
11 Topstitch fold edge sleeve Nikki
Anna
1L Join and mark neck rib and Rose
3 prestitch Cindy Abby
Vivian 12 Bartack 1cm at edge sleeve 2x Jenny
4 4OL Attach neck Rib Michelle 13 2CO Topstitch bottom hemming Matt
Maya Charlie
Debbie 14 Bartack 1cm at bottom hemming Irene
4OL Attach sleeve 2x + marking
5 OPR Cut back neck excess Clara 15 body Nadya
6 1L Attach back neck tape Jessica Karina
Sarah Clarissa
7 1L Join Label 4 Ply STD Maria 16 4OL Join sideseam Amanda
Dewi Eva
Hana Rachel
CYCLE LINE BALANCING 2A- Identify number of
operators that you need per
Step by Step: operation
Line balancing rate

1.List down all the 4. Calculate the

operations capacity per hour of
breakdown in each operator per
sequence operation

2. Identify how
3. Identify/assign
many pieces per
the operators for
hour/day is required
each operation
by planning: target
CALCULATE OUTPUT AT 100% EFFICIENCY

requested Pieces Actual

Cycle
SMV SMV per hour production
Operation output (in Sec.) (Mins) at 100%
Operator time
capacity
(Per hr.) (sec)
Eff per hour
Seq

1 Loading T-shirt Short Sleeve 80 32.718 0.5453 110.03 Kevin 78 46.15

80 32.718 0.5453 110.03 Paul 65 55.38

Pieces per hour 60 min/hour

at 100% eff 0.5453 min/pc
CALCULATE OUTPUT AT 100% EFFICIENCY

requested Pieces Actual

Cycle
SMV SMV per hour production
Operation output (in Sec.) (Mins) at 100%
Operator time
capacity
(Per hr.) (sec)
Eff per hour
Seq

1 Loading T-shirt Short Sleeve 80 32.718 0.5453 110.03 Kevin 78 46.15

80 32.718 0.5453 110.03 Paul 65 55.38

Pieces per hour 60 min/hour

at 100% eff 0.5453 min/pc
CALCULATE CAPACITY PER OPERATOR: CYCLE TIME

requeste Pieces
Cycle
SMV SMV per hour
Operation d output (in Sec.) (Mins) at 100% Operator time
(Per hr.) (sec)
Eff
Seq

1 Loading T-shirt Short Sleeve 80 32.718 0.5453 110.03 Kevin 78

80 32.718 0.5453 110.03 Paul 65

To calculate the capacity per operation we need:

Running Take Cycle

Style/Existing time: use
line latest capture
Cycle time when
New Use historical
style/New cycle time
line data
CALCULATE CAPACITY PER OPERATOR: PIECES PER HOUR

requeste Pieces Actual

Cycle
SMV SMV per hour production
Operation d output (in Sec.) (Mins) at 100% Operator time capacity
(Per hr.) (sec)
Eff per hour
Seq

1 Loading T-shirt Short Sleeve 80 32.718 0.5453 110.03 Kevin 78 46.15

80 32.718 0.5453 110.03 Paul 65 55.38

Pieces per hour 60 min/hour

(Kevin capacity) Cycle time (min)

Pieces per hour 60 min/hour

46.15 pcs /hour
(Kevin capacity) 1.3 min/pc

Pieces per hour 60 min/hour

55.38 pcs /hour
(Paul capacity) 1.08 min/pc
 CALCULATE INDIVIDUAL EFFICIENCY
First let’s review the formula:

output # pcs * SMV

Efficiency
input # operators*worked minutes

1 pcs * SMV SMV

Efficiency
1 operator*worked minutes Cycle Time
 CALCULATE INDIVIDUAL EFFICIENCY

requested Pieces per

SMV Actual production Efficiency
Operation output (in Sec.)
SMV (Mins) hour at 100% Operator Cycle time (sec)
capacity per hour (capacity)
Eff
(Per hr.)
Seq
1Loading T-shirt Short Sleeve 80 32.718 0.5453 110.03 Kevin 78 46.15 41.9%
80 32.718 0.5453 110.03 Paul 65 55.38 50.3%

32.718
Kevin Efficiency 41.9%
78

32.718 50.3%
Paul Efficiency
65
CYCLE LINE BALANCING
Step by Step:
1. List down all the
operations
breakdown in
sequence

2. Identify how 5. Compare total

many pieces per actual capacity in
hour/day is required the operation
by planning: target against target

4. Calculate the
3. Identify/assign
capacity per hour of
the operators for
each operator per
each operation
operation
 Compare total Capacity with the target

Actual
requested Pieces per
SMV Cycle production Efficiency
Operation output SMV (Mins) hour at 100% Operator
(in Sec.) time (sec) capacity per (capacity)
(Per hr.) Eff
hour
Seq
Loading T-shirt Short
80 Kevin
1 Sleeve 32.718 0.5453 110.03 78 46.15 41.9%
80 Paul
32.718 0.5453 110.03 65 55.38 50.3%

TOTAL 101.53
46.15 + 55.38
CAPACITY
CYCLE TIME- LINE BALANCING
Step by Step:
1. List down all the 6. Adjust the balance
operations if more capacity is
breakdown in required or transfer
sequence available time

2. Identify how many 5. Compare total

pieces per hour/day actual capacity in the
is required by operation against
planning: target target

4. Calculate the
3. Identify/assign the
capacity per hour of
operators for each
each operator per
operation
operation
CYCLE LINE BALANCING
Step by Step:

6. Adjust the balance if more

capacity is required or transfer
available time

a. Assign d. Calculate
pieces b. Calculate operator e. Calculate
c. Calculate
according to used minutes efficiency in available f. Analyze:
earned
higher per hour, per the line time operation by
minutes per
efficiency. day balance operation:
hour, per day
assign more
operations/
reduce
operators
CYCLE LINE BALANCING
Step by Step:

6. Adjust the balance if more

capacity is required or transfer
available time

a. Assign b. Calculate c. Calculate d. Calculate e. Calculate

f. Analyze:
pieces used earned operator available
operation
according minutes per minutes per efficiency in time
by
to higher hour, per hour, per the line operation:
efficiency. day day balance assign more
operations/
reduce
operators
 Assign
requested Pieces Actual ed
SMV SMV per hour Cycle production Efficiency
Operation output (in Sec.) (Mins) at 100%
Operator
time (sec) capacity (capacity) pieces
(Per hr.) Eff per hour per
Seq hour
Loading T-shirt Short
80 Kevin
1 Sleeve 32.718 0.5453 110.03 78 46.15 41.9% 25

80 Paul
32.718 0.5453 110.03 65 55.38 50.3% 55

80

TOTAL CAPACITY 46.15 + 55.38 101.53

Are we going to produce 101 pcs or 80 pcs?
How many pcs each operator?- (discuss)
Assign operators starting for the highest efficiency
CYCLE LINE BALANCING
Step by Step:

6. Adjust the balance if more

capacity is required or transfer
available time

a. Assign b. Calculate c. Calculate d. Calculate e. Calculate

f. Analyze:
pieces used earned operator available
operation
according minutes per minutes per efficiency in time
by
to higher hour, per hour, per the line operation:
efficiency. day day balance assign more
operations/
reduce
operators
 Actual
requeste Pieces per Cycle Assigned Used
SMV SMV production Efficiency total Used Earned
Operation d output hour at Operator time pieces Minutes
(in Sec.) (Mins) capacity (capacity) minutes hours
(Per hr.) 100% Eff (sec) per hour per hour
per hour
eq

Loading 80 32.718 0.5453 110.03 Kevin 78 41.9% 25 32.5 260.00

1 T-shirt 46.15 109.06
Short
Sleeve 80 32.718 0.5453 110.03 Paul 65 50.3% 55 60 480.00 241.61
55.38

Used minutes per Assigned pieces per Cycle time in minutes

hour hour

Kevin: Used minutes per hour 25 (78 / 60)

Paul: Used minutes per hour 55 (65 / 60)

CYCLE LINE BALANCING
Step by Step:

6. Adjust the balance if more

capacity is required or transfer
available time

a. Assign b. Calculate c. Calculate d. Calculate e. Calculate

f. Analyze:
pieces used earned operator available
operation
according minutes per minutes per efficiency in time
by
to higher hour, per hour, per the line operation:
efficiency. day day balance assign more
operations/
reduce
operators
 request
Actual
ed Pieces per Cycle Assigned Used
SMV SMV production Efficiency total Used Earned
Operation output hour at Operator time pieces Minutes
(in Sec.) (Mins) capacity (capacity) minutes minutes
(Per 100% Eff (sec) per hour per hour
per hour
hr.)
eq

Loading 80 32.718 0.5453 110.03 Kevin 78 41.9% 25 32.5 109.06

1 T-shirt 46.15 260.00
Short
Sleeve 80 32.718 0.5453 110.03 Paul 65
55.38
50.3% 55 60
480.00
241.61

Total minutes used Total minutes earned

Cycle time * assigned pieces * hrs per day SMV * assigned pieces * hrs per day

(78/60) * 25 * 8 (0.5453) * 25 * 8
Used minutes are need it to know the operator’s available time.
Earned minutes are need it to calculate efficiency
CYCLE LINE BALANCING
Step by Step:

6. Adjust the balance if more

capacity is required or transfer
available time

a. Assign b. Calculate c. Calculate d. Calculate e. Calculate

f. Analyze:
pieces used earned operator available
operation
according minutes per minutes per efficiency in time
by
to higher hour, per hour, per the line operation:
efficiency. day day balance assign more
operations/
reduce
operators
 reque
Actual Assigne
sted Cycl
Pieces per producti d Used total worked
outpu SMV Operato e Efficiency Earned Actual
Operation t (in Sec.)
SMV (Mins) hour at
r time
on
(capacity)
pieces Minutes Used
hours
minute
Efficiency
100% Eff capacity per per hour minutes s
(Per (sec)
per hour hour
Seq hr.)
Loading 80 32.718 0.5453 110.03 Kevin 78 41.9% 25 32.5 260 109.06 480 22.7%
1 T-shirt 46.15
Short
Sleeve 80 32.718 0.5453 110.03 Paul 65
55.38
50.3% 55 60 480 241.61 480 50.3%

Operator Assigned pcs per hour Hours per day SMV

efficiency in LB
Hours per day 60

Kevin efficiency 25 8 0.5453

22.7%
in LB
8 60
Continue calculating individual efficiency for each operator in all
operations
 Earned Minutes Worked minutes Efficiency
Abby 82.84 480.00 17.26% Continue
Amanda 270.16 480.00 56.28% calculating the
Anna 136.65 480.00 28.47%
Charlie 231.13 480.00 48.15% individual efficiency
Cindy 91.13 480.00 18.99% for each operator
Clara 170.30 480.00 35.48%
Clarissa 185.77 480.00 38.70% and for all
Debbie 213.24 480.00 44.42% operations.
Dewi 158.92 480.00 33.11%
Eva 275.79 480.00 57.46%
Grace 324.74 480.00 67.65%
Hana 17.00 480.00 3.54%
Irene - 480.00 0.00%
Remember: you need to
Jazmine 249.98 480.00 52.08%
calculate earned minutes
Jenny 153.66 480.00 32.01%
for each operation in case
Jessica 123.49 480.00 25.73%
the operator needs to do
more than 1 operation
CYCLE LINE BALANCING
Step by Step:

6. Adjust the balance if more

capacity is required or transfer
available time

a. Assign b. Calculate c. Calculate d. Calculate e. Calculate

Analyze:
pieces used earned operator available
operation
according minutes per minutes per efficiency in time
by
to higher hour, per hour, per the line operation:
efficiency. day day balance assign more
operations/
reduce
operatos
 requ Actual
Assig
ested Pieces product Efficienc Used
Cycle ned total Actual
outp SMV SMV per hour Operato ion y Minut Earned worked Available
Operation time piece Used Efficienc
ut (in Sec.) (Mins) at 100% r capacity (capacity es per hours minutes minutes
(sec) s per minutes y
(Per Eff per ) hour
hour
Seq hr.) hour
Loading
80 Kevin
1 T-shirt 32.718 0.5453 110.03 7846.15 41.9% 25 32.5 260 109.06 480 22.7%220.00
Short
Sleeve 80 Paul
32.718 0.5453 110.03 6555.38 50.3% 55 60 480 241.61 480 50.3% -

80 -

Available time Worked minutes Total used minutes

Kevin efficiency in LB 480 260

Continue identifying all the available time for all operators in all
operations
Operator Available minutes
Abby 284.40
Amanda -
Anna - Continue with the same
Charlie -
Cindy 228.00 analysis operation by
Clara 288.00
Clarissa - operation, identify available
Debbie -
Dewi - time for all the operators and
Eva -
Grace 149.33 list out.
Hana 391.33
Irene 480.00
Jazmine -
Jenny 42.67
Jessica 66.13
Joan -
John 234.00
Karina -
Kevin 220.00
Kim -
Maria -
Matt -
Maya 62.93
Michelle -
Nadya -
Nikki -
Paul -
Rachel 341.60
CYCLE LINE BALANCING
Step by Step:

6. Adjust the balance if more

capacity is required or transfer
available time

a. Assign b. Calculate c. Calculate d. Calculate e. Calculate

f. Analyze:
pieces used earned operator available
operation
according minutes per minutes per efficiency in time
by
to higher hour, per hour, per the line operation:
efficiency. day day balance assign more
operations/
reduce
operators
During the analysis process you need to:
1. Identify what operators :

a. needs to increase efficiency.

b. needs re-training and set up training curve for the

actual operation

c. Need to learn new operation.

2. Revised lay-out if need it according to LB.

3. Re-allocate operators that are no longer need it in the line.

4. Calculate individual efficiency.

 Analyze each operation with your group, think about
Exercise 2 what options, what possible decisions we can make
requested Actual Assigned Used total Actual Availabl
Pieces per
SMV SMV Cycle time production Efficiency Earned worked
Operation output (in Sec.) (Mins)
hour at Operator
(sec) capacity per (capacity) pieces Minutes Used Efficienc e
100% Eff hours minutes
Seq
(Per hr.) hour per hour per hour minutes y minutes
Loading T-shirt Short
80 Kevin
1 Sleeve 32.718 0.5453 110.03 78 46.15 41.9% 25 32.5 260.00 109.06 480.00 22.7% 220.00
80 Paul
32.718 0.5453 110.03 65 55.38 50.3% 55 60 480.00 241.61 480.00 50.3% -

80 -

80 John
2 4OL Join Shouder 30.462 0.5077 118.18 123 29.27 24.8% 15 30.75 246.00 60.92 480.00 12.7% 234.00
80
30.462 0.5077 118.18 Sharon 114 31.58 26.7% 32 60 480.00 128.26 480.00 26.7% -
80
30.462 0.5077 118.18 Anna 107 33.64 28.5% 34 60 480.00 136.65 480.00 28.5% -
80
30.462 0.5077 118.18
80

1L Join and mark neck

80
3 riband prestitch 25.314 0.4219 142.21 Cindy 70 51.43 36.2% 27 31.5 252.00 91.13 480.00 19.0% 228.00
80
25.314 0.4219 142.21 Vivian 67 53.73 37.8% 54 60 480.00 181.35 480.00 37.8% -
80.73

80
4 4OL Attach neck Rib 55.53 0.9255 64.83 Michelle 124 29.03 44.8% 29 60 480.00 214.95 480.00 44.8% -
80
55.53 0.9255 64.83 Maya 136 26.47 40.8% 23 52.13333 417.07 170.29 480.00 35.5% 62.93
80
55.53 0.9255 64.83 Debbie 125 28.80 44.4% 29 60 480.00 213.24 480.00 44.4% -
80.8322
6
CYCLE LINE BALANCING
Step by Step:
7. When finish the
6. Adjust the balance analysis of all
1. List down all the
if more capacity is operations: calculate
operations breakdown
required or transfer the efficiency target
in sequence
available time of the final line
balance

2. Identify how many 5. Compare total

pieces per hour/day is actual capacity in the
required by planning: operation against
target target

4. Calculate the
3. Identify/assign the
capacity per hour of
operators for each
each operator per
operation
operation
 Initial Line Balance Efficiency
Earned Minutes Worked minutes
Abby 82.84 480.00 1. List out all operators
Amanda 270.16 480.00
Anna 136.65 480.00
2. Identify earned minutes
Charlie 231.13 480.00 according to LB assignment
Cindy 91.13 480.00
Clara 170.30 480.00 3. Sum up all earned minutes and
Clarissa
Debbie
185.77
213.24
480.00
480.00
all worked minutes
Dewi 158.92 480.00 4. Calculate efficiency
Eva 275.79 480.00
Grace 324.74 480.00
Hana 17.00 480.00
Irene - 480.00 Total Earned
Jazmine 249.98 480.00
Jenny 153.66 480.00 minutes
Jessica 123.49 480.00
Line Efficiency
Joan 64.24 480.00 Total worked
John 60.92 480.00 minutes
Karina 334.38 480.00
Kevin 109.06 480.00
Kim 121.98 480.00
Maria 97.12 480.00
Matt 154.74 480.00 5,654
Maya 170.29 480.00 Line Efficiency
Michelle 214.95 480.00
Nadya 202.33 480.00
15,840
Nikki 295.87 480.00
Paul 241.61 480.00
Rachel 44.13 480.00
Rose 360.19 480.00
Sarah 187.74 480.00 Line Efficiency 35.69%
Sharon 128.26 480.00
Vivian 181.35 480.00
5,654.00 15,840.00
 Improved Line Balance Efficiency
Unused minutes Used minutes Earned Minutes Worked minutes
Abby - - - -
Amanda - 480.00 270.16 480.00 1. List out all operators
Anna - 480.00 136.65 480.00 2. Identify earned minutes
Charlie - 480.00 231.13 480.00
Cindy - - - - according to LB assignment
Clara
Clarissa
36.00
-
444.00
480.00
261.43
185.77
480.00
480.00
3. Sum up all earned minutes and
Debbie - 480.00 213.24 480.00 all worked minutes
Dewi - 480.00 158.92 480.00
Eva - 480.00 275.79 480.00
4. Calculate efficiency
Grace 5.33 474.67 368.86 480.00
Hana 139.33 340.67 99.84 480.00
Irene
Jazmine
42.67
-
437.33
480.00
123.39
249.98
480.00
480.00
Total Earned
Jenny 42.67 437.33 153.66 480.00 minutes
Jessica 66.13 413.87 123.49 480.00 Line Efficiency
Joan - 480.00 64.24 480.00
John 234.00 246.00 60.92 480.00
Total worked
Karina - 480.00 334.38 480.00 minutes
Kevin 220.00 260.00 109.06 480.00
Kim - 480.00 121.98 480.00
Maria - 480.00 97.12 480.00
Matt - 480.00 154.74 480.00
Maya 62.93 417.07 170.29 480.00 5,777.39
Michelle - 480.00 214.95 480.00 Line Efficiency
Nadya - 480.00 202.33 480.00
14,400
Nikki - 480.00 295.87 480.00
Paul - 480.00 241.61 480.00
Rachel - - - -
Rose - 480.00 360.19 480.00
Sarah - 480.00 187.74 480.00
Sharon - 480.00 128.26 480.00
Line Efficiency 40.12%
Vivian - 480.00 181.35 480.00
849.07 5,777.39 14,400.00
CYCLE LINE BALANCING
Step by Step:
6. Adjust the
1. List down all the 7. When finish
balance if more
operations the analysis of all
capacity is required
breakdown in operations:
or transfer available
sequence calculate the
time
efficiency target
2. Identify how of the final line
5. Compare total balance
many pieces per
actual capacity in
hour/day is
the operation
required by
against target
planning: target 8. Identify the
operators that still
4. Calculate the have available time:
3. Identify/assign re-training plan
capacity per hour of
the operators for
each operator per
each operation
operation
 LINE BALANCING
CYCLE TIME
BENEFITS
Can be done according to planned efficiency target

Consider standard SMV and individual cycle time to

drive efficiency

Identify available time per operator: assign other

operation or plan re-training

Reduce WIP by operation, avoid over-production

 TAKT TIME
PRO’S
• Tool to plan the initial line balance
according to demand.
• Suitable for big volume orders.
• Considers only cycle time for balancing.
• No clear visibility of available time.
• Operation improvement based on cycle
times higher than the takt time.
CON’S
Target and /or expected efficiency not
being considered.
When activities cannot be transfer
(semi automated operation) then is
challenging to be able to balance
following the takt time.
Fast beat-fast line, slow beat-slow line.
CYCLE TIME
PRO’S
• Line balance can be done according
to the planned efficiency target.
• Suitable for any order size.
• Consider standard SMV and
individual cycle time to drive
efficiency.
CON’S
Cycle time needs to be
updated and rebalance on a
regular basis.
 TAKT TIME OR CYCLE TIME
WHEN TO APPLY
TAKT TIME
PLANNING/PREPARATION

CYCLE TIME
PREPARE FOR PRODUCTION AND
EFFICIENCY IMPROVEMENTS
Q&A
THANK YOU