ME 2020 One Pager Rollout

March 2020
Initiative:
Line Balance Rate Baseline more than 65%
Line Balance Rate Improvement by 5%

2
Initiative: Line Balance Base Line and Improvement 5%

Background: Why we want to do that?

Line Balance: Benefits of Line Balance: Prior to style changeover, a line

balance plan is used to determine:
Way of adjusting each operator’s 1. Everyone is doing the same
loading to make each operation’s amount of work • Machine Requirement:
time value almost the same. • Number of units
2. Doing the same amount of work • Machine type
to customer requirement
• Operator:
3. No one overburdened • Number of operators
• Required skill level
4. Variation is ‘smoothed’
• Sequence of Operations in the
5. No one waiting production line

6. Everyone working together in a

BALANCED fashion
Initiative: Line Balance Base Line and Improvement 5%

How to Achieve?

Why balancing is important in • How to determine bottleneck How to Analyze the Line Balance?
setting up the line? operation?
To eliminate excessive work in • Through WIP Using Time Observation Sheet:
progress (WIP) or bottlenecks (Work In Progress) • Production output
• Cycle Time Check • SMV
What is Bottleneck? • Cycle Time
• Operators completing sewing How to Achieve the Line Balance?
operations of higher SMV’s,
compared to all other operators • Identify the constraint
(bottleneck)
• Holds up the work for operators • Squeeze the constraint
further down the line causing • Support the constraint
production stoppages • Elevate the constraint
• Do not let the inertia become
the constraint
Initiative: Line Balance Base Line and Improvement 5%

How to Measure and Track the Progress?

Line Balancing Process:

CYCLE TIME
How to calculate the Line Balance Rate?
• Share Method
• Rearrange bottleneck
operation
LBR= Total Cycle Time X Bottleneck* X • Improve the bottleneck
100% operation to reduce it’s time
OPERATOR 1 2 3 4 5
number of total cycle time value
operators • Improve handling & fabricate
machine folders &
attachments

CYCLE TIME
Target Line Balance Rate > 65%
• Reduce cycle time by
additional/shared operator
*Bottleneck cycle time means highest cycle time • Separate & Eliminate
of the operator
operation elements
OPERATOR 1 2 3 4 5
 Summary Activity: Line Balance

Build Sewer
Database / • IE updates highest potential efficiency of the sewer on the Sewer Database
1 Pre-set Before QCO • IE use the Sewer Database for initial line balancing and sewing line layout
• Design the line balance chart using historical data
Line Balance

• IE continuously monitor actual efficiency of the sewer and update the data
• Review quality level, if it is consistent after 2 hours of continuous production then
2
First actual During QCO do the new Balance
Line Balance • Create actual line balance chart

• IE conduct cycle study, update LB Graph compared with target LB rate

Line balancing • IE identify the constraint operation to make sure they have correct method, right
3 study in 2nd days After QCO quality, speed and appropriate number of operators.
after changeover • Update the line balance chart

Review the line • IE continuously monitor actual performance of the sewer and update the data
4
After QCO • Optimize the right number of operators to improve the LB rate (example: from
balance 5th day 3 to 2.5 operators)
after changeover
T1: LB should be updated at the end of each line
LINE BALANCE TRACKING LIST

COPT (*SMV) Day I Efficiency Day 4 Efficiency Reason for

Changeover Changeover
Line Name Latest LBR missing
Date Category Target
Actual COPT Actual Target Actual Target target
COPT
Line
balance% is
LINE 11 17-Jan A 8 6 35% 40% 75% 70%
lower than
80%
Line
balance% is
LINE 11 25-Jan B 8 5 40% 50% 75% 70%
lower than
80%
 IE:_______________________
SCENARIO#1- 1 OPERATOR SUPPORTS BOTTLENECK OPERATION Line Leader:________________
(OPERATION#3) Date:______________________
LINE BALANCING GRAPH IN EACH LINE LBR Calculation: _____________
BEFORE LINE BALANCING

• LBR =(24+23+35+26+28)/5*35*100% = 78%

40 120%

35
100%
Seconds

30 30
80%
25

20 60%
35
15
28 40%
26
24 23
10
20%
5

0 0%
Operator 1 Operator 2 Operator 3 Operator 4 Operator 5
Cycle time Takt Time Efficiency

8
SCENARIO#1- LINE BALANCING GRAPH IN EACH LINE IE:_______________________
DURING LINE BALANCING- ONE OPERATOR MANAGE TWO OPERATIONS Line Leader:________________
Date:______________________
• Identify Operator#3 is bottleneck LBR Calculation: _____________
• Kaizen for operator#3 method or improve operator#3 skill
• Consider neighbor operator(Operator#2) to support bottleneck operation if operator#3 can not meet takt
time after initial kaizen
• In our case, we will shift operator#3 ’s work to operator#2, then how to calculate operator 2's cycle time?
40 120%

35
100%
Seconds

30 30
80%
25 ?

20 60%
35
15
28 40%
26
24 23
10
20%
5

0 0%
Operator 1 Operator 2 Operator 3 Operator 4 Operator 5
Cycle time Takt Time Efficiency

9
SCENARIO #1- HOW TO CALCULATE OPERATOR 2 CYCLE TIME IN LINE BALANCE CHART?

Given:
1. Takt time is 30 seconds
2. Operator#3 Cycle time is 35sec, which is the bottleneck, operator#2 is 23 sec, they physically close each
other
3. We ask operator#2 partially to support operator #3, but even that, operator#2 is less than takt time
4. When operator #2 performs operator #3 ‘s operation, the cycle time will be: 40 secs
Question: how to calculate operator#2 cycle time in line balance chart?
Solution:
1. Takt time is 30 sec, then hourly target output will be: 60mins*60secs/30secs=120pcs
2. Operator #3 hourly output: 60mins*60secs/35secs=102 pcs
3. The hourly gap: 120 -102= 18 pcs, which we will rely on operator#2
4. Then operator #2 cycle time will be weighted average cycle time:( Operator#2 cycle time for operation#2
*hourly target output+ operator#2’s cycle time for operation#3* additional output of operation#3 by
operator#2 ) / target output in takt time
= (23secs *120pcs+40secs*18 pcs)/120pcs= 29secs

15-JAN-2020 10
SCENARIO #1- HOW TO CALCULATE OPERATOR 2 CYCLE TIME IN LINE BALANCE CHART?

Total seconds in an hour Takt time Hourly target output in takt time

3600SECS 30 120PCS

Operator#3 cycle time for operation #3 Total seconds in an hour Operator#3’s output for operation#3

35SECS 3600SECS 102PCS

How many pcs operator#2 needs to

Operator#2 cycle time for operation #2 Operator#2’s cycle time for operation#3 support operation#3?
Total seconds in an hour

23SECS 40SECS 18PCS

Additional output of
Operator#2 cycle Hourly target output Operator#2’s cycle
120PCS 40SECS operation#3
18PCS by
time for23SECS
operation #2 in takt time time for operation#3
operator#2
Operator#2
New cycle 29SECS
time
Hourly 120PCS
target output
in takt time

15-JAN-2020 11
 IE:_______________________
SCENARIO #1- LINE BALANCING GRAPH AFTER LINE Line Leader:________________
BALANCING Date:______________________
LBR Calculation: _____________

• LBR =(24+29+30+26+28)/5*30*100% = 91%

35 120%

30 30 100%
Seconds

6
25
80%

20
60%
15 30
28
26
24 23 40%
10

20%
5

0 0%
Operator 1 Operator 2 Operator 3 Operator 4 Operator 5
Cycle time Takt Time Efficiency

12
 IE:_______________________
SCENARIO#2 - 2 OPERATORS PERFORM ONE OPERATION Line Leader:________________
(OPERATION #3 ) Date:______________________
LINE BALANCING GRAPH IN EACH LINE LBR Calculation: _____________
BEFORE LINE BALANCING

• LBR =(24+23+55+26+28)/5*55*100% = 57%

60 120%

50 100%
Seconds

40 80%

30 30 60%
55

20 40%

26 28
24 23
10 20%

0 0%
Operator 1 Operator 2 Operator 3 Operator 4 Operator 5
Cycle time Takt Time Efficiency

13
 IE:_______________________
SCENARIO#2 - 2 OPERATORS PERFORM ONE OPERATION Line Leader:________________
(OPERATION #3 ) Date:______________________
LBR Calculation: _____________
• Operation#3 is bottleneck operation, far higher than
the takt time(30secs), we will assign 2 operators for
operation#3

35 120%

30 30 100%
Seconds

25
80%

20
60%
15
28
? ? 26
24 23 40%
10

20%
5

0 0%
Operator 1 Operator 2 Operator 3-1 Operator 3-2 Operator 4 Operator 5
Cycle time Takt Time Efficiency

14
SCENARIO#2 - HOW TO CALCULATE OPERATOR 3-1&2 CYCLE TIME IN LINE BALANCE
CHART?
Given:
1. Takt time is 30 seconds
2. Operation #3 Cycle time is 55secs, which is the bottleneck
3. We assigned 2 operators (Operator3-1, Operator 3-2) to perform Operation #3
4. Actual cycle time:
• When Operator 3-1 performs Operation #3, the cycle time is 63secs
• When Operator 3-2 performs Operation #3, the cycle time is 55 secs
Question: how to calculate operator 3-1&3-2 cycle time in line balance chart? and what is new LBR%?
Solution:
1. Takt time is 30 sec, then hourly output will be: 60mins*60secs/30secs=120pcs
2. Operator #3-2 cycle time is competitive, so we will fully deploy Operator #3-2 in operation #3
3. Hourly output for Operator #3-2 : 60mins*60secs/55secs=65 pcs
4. The hourly gap: 120 -65= 55 pcs, which we will rely on Operator 3-1
5. Operator #3-2 cycle time in line balance chart will be: 55secs*65pcs/120pcs=30 secs
6. Operator #3-1 cycle time in line balance chart will be: 63secs*55pcs/120pcs= 28.8 secs

15-JAN-2020 15
 IE:_______________________
SCENARIO#2 - LINE BALANCING GRAPH BEFORE LINE Line Leader:________________
BALANCING Date:______________________
BEFORE LINE BALANCING LBR Calculation: _____________

• LBR =(24+23+55+26+28)/5*55*100% = 57%

60 120%

50 100%
Seconds

40 80%

30 30 60%
55

20 40%

26 28
24 23
10 20%

0 0%
Operator 1 Operator 2 Operator 3 Operator 4 Operator 5
Cycle time Takt Time Efficiency

16
 IE:_______________________
SCENARIO#2 - LINE BALANCING GRAPH AFTER LINE Line Leader:________________
BALANCING Date:______________________
LBR Calculation: _____________

• LBR =(24+23+28.8+30+26+28)/6*30*100% = 89%

35 120%

30 30 100%
Seconds

25
80%

20
60%
15 28.8 30
28
26
24 23 40%
10

20%
5

0 0%
Operator 1 Operator 2 Operator 3-1 Operator 3-2 Operator 4 Operator 5
Cycle time Takt Time Efficiency

17
 IE:_______________________
SCENARIO#3 - 2 OPERATORS PERFORM ONE OPERATION Line Leader:________________
(OPERATION #3 ), ONE OF OPERATORS NOT DELICATED, BUT Date:______________________
SUPPORTS 2 LINES LBR Calculation: _____________
LINE BALANCING GRAPH IN EACH LINE
BEFORE LINE BALANCING
• LBR =(24+23+35+26+28)/5*35*100% = 77.7%

40 120%

35
100%
Seconds

30 30
80%
25

20 60%
35
15
28 40%
26
24 23
10
20%
5

0 0%
Operator 1 Operator 2 Operator 3 Operator 4 Operator 5
Cycle time Takt Time Efficiency

18
SCENARIO#3-1 - HOW TO CALCULATE OPERATOR 3-1&2 CYCLE TIME IN LINE BALANCE
CHART?
Given:
1. Takt time is 30 seconds
2. Operation #3 Cycle time is 35secs, which is the bottleneck
3. We assigned 2 operators (Operator3-1, Operator 3-2) to perform Operation #3,but one of operators will
also support another line, not dedicated to this line
4. Actual cycle time:
• When Operator 3-1 performs Operation #3, the cycle time is 38secs
• When Operator 3-2 performs Operation #3, the cycle time is 40 secs
Question: how to calculate operator 3-1&3-2 cycle time in line balance chart? and what is new LBR%?
Solution:
1. Takt time is 30s, Operation 3 is bottleneck
2. we assign 2 operators in operation#3, they are 3-1 and 3-2
3. 3-1 is more capable of operation 3, therefore 3-1 will be 100% deployed
4. the output for 3-1 is 3600/38=94pcs
5. the target output is :3600/30=120pcs
6. then 3-2 needs to support 120-94=26pcs
15-JAN-2020 19
SCENARIO#3-2 - HOW TO CALCULATE OPERATOR 3-1&2 CYCLE TIME IN LINE BALANCE
CHART?
Question: how to calculate operator 3-1&3-2 cycle time in line balance chart? and what is new LBR%?
Solution(Continued) :
7. Then operation #3 cycle time will be:
8. (94*38+26*40)/120=38.4s
9. Operator 3-1: 30s, Operator 3-2: 8.4
10. Operator 3-2 will be low level engaged in operation#3, the time will be: 26*40=1040
11. % of operator 3-2 involved in operation#3 in 1 hour
=>1040/3600=0.29
12. LBR%= (24+23+30+8.4+26+28)/(30*(5+0.29))=87.8%

15-JAN-2020 20
 IE:_______________________
SCENARIO#3-3 LINE BALANCING GRAPH BEFORE LINE Line Leader:________________
BALANCING Date:______________________
BEFORE LINE BALANCING LBR Calculation: _____________

• LBR =(24+23+35+26+28)/5*30*100% = 77.7%

40 120%

35
100%
Seconds

30 30
80%
25

20 60%
35
15
28 40%
26
24 23
10
20%
5

0 0%
Operator 1 Operator 2 Operator 3 Operator 4 Operator 5
Cycle time Takt Time Efficiency

21
 IE:_______________________
SCENARIO#3-4 LINE BALANCING GRAPH AFTER LINE Line Leader:________________
BALANCING Date:______________________
LBR Calculation: _____________

• LBR =(24+23+30+8.4+26+28)/(5+0.29)*30*100% = 87.8%

35 120%

30 30 100%
Seconds

25
80%

20 71%
60%
15 30
28
26
24 23 40%
10

20%
5
8.4

0 0%
Operator 1 Operator 2 Operator 3-1 Operator 3-2 Operator 4 Operator 5
Cycle time Takt Time Efficiency

22
 IE:_______________________
SCENARIO#4 - 2 OPERATORS PERFORM ONE OPERATION Line Leader:________________
(OPERATION #3 ), ONE OF OPERATORS NOT DEDICATED, BUT Date:______________________
SUPPORTS 2 LINES WITH NEW BOTTLENECK AFTER REBALANCING LINE LBR Calculation: _____________
LINE BALANCING GRAPH IN EACH LINE
BEFORE LINE BALANCING
• LBR =(24+23+35+26+28)/5*35*100% = 77.7%

40

35
Seconds

30

25 26

20
35
15
28
26
24 23
10

0
Operator 1 Operator 2 Operator 3 Operator 4 Operator 5
Cycle time Takt Time

23
SCENARIO#4-1 - HOW TO CALCULATE OPERATOR 3-1&2 CYCLE TIME IN LINE BALANCE
CHART?
Given:
1. Takt time is 26 seconds
2. Operation #3 Cycle time is 35secs, which is the bottleneck
3. We assigned 2 operators (Operator3-1, Operator 3-2) to perform Operation #3, but one of operators will
also support another line, not dedicated to this line
4. Actual cycle time:
• When Operator 3-1 performs Operation #3, the cycle time is 38secs
• When Operator 3-2 performs Operation #3, the cycle time is 40 secs
5. But when we rebalance the operation#3 with 2 operators, then operation#5 will be new bottleneck
Question: how to calculate operator 3-1&3-2 cycle time in line balance chart? and what is new LBR%?
Solution:
1. Takt time is 26s, Operation 3 is bottleneck
2. we assign 2 operators in operation#3, they are 3-1 and 3-2
3. 3-1 is more capable of operation 3, therefore 3-1 will be 100% deployed
4. the output for 3-1 is 3600/38=94pcs
5. the target output is :3600/28=128.5pcs, round down to 128 pcs (based on new bottleneck-operation#5)
6. then 3-2 needs to support 128-94=34pcs 15-JAN-2020 24
SCENARIO#4-2 - HOW TO CALCULATE OPERATOR 3-1&2 CYCLE TIME IN LINE BALANCE
CHART?
Question: how to calculate operator 3-1&3-2 cycle time in line balance chart? and what is new LBR%?
Solution(Continued) :
7. Then operation #3 cycle time will be:
8. (94*38+34*40)/128=38.5s
9. Operator 3-1: 28 s, Operator 3-2: 10.5s
10. Operator 3-2 will be low level engaged in operation#3, the time will be: 34*40=1360s
11. % of operator 3-2 involved in operation#3 in 1 hour
=>1360/3600=0.38
12. LBR%= (24+23+28+10.5+26+28)/(28*(5+0.38))=92.6%

p.s. this line capacity is not enough, the expected output is 138pcs ( 3600/26) per hour, actual output is only 128pcs per hour

15-JAN-2020 25
 IE:_______________________
SCENARIO#4-3 LINE BALANCING GRAPH BEFORE LINE Line Leader:________________
BALANCING Date:______________________
BEFORE LINE BALANCING LBR Calculation: _____________

• LBR =(24+23+35+26+28)/5*30*100% = 77.7%

40 120%

35
100%
Seconds

30

26 80%
25

20 60%
35
15
28 40%
26
24 23
10
20%
5

0 0%
Operator 1 Operator 2 Operator 3 Operator 4 Operator 5
Cycle time Takt Time Efficiency

26
 IE:_______________________
SCENARIO#4-4 LINE BALANCING GRAPH AFTER LINE Line Leader:________________
BALANCING Date:______________________
LBR Calculation: _____________

• LBR =(24+23+28+10.5+26+28)/(5+0.38)*28*100% = 92.6%

30

26
25
Seconds

20
62%

15
28 28
26
24 23
10

5 10.5

0
Operator 1 Operator 2 Operator 3-1 Operator 3-2 Operator 4 Operator 5
Cycle time Takt Time

27
 IE:_________________________
LINE BALANCING GRAPH IN EACH LINE Line Leader:_________________

Line balancing graph display: latest line balance graph with cycle time by operator,
takt time, line balancing rate.

28
Thank you
 CHANGEOVER EXECUTION TRACKING

CHANGEOVER EXECUTION ANALYSIS

Line Number
QCO Execution Bndl Size
QCO date
19-Feb-20
Old Style code Old style Last piece out time 1:15
Analysis 5 New Style code Next style 1st. good piece out time 1:20
0Hr 05Min 0Hr 50Min
MC Mc Stng Mc Stng 1st Bundle MC Setting MC Setting start
Sr Operation SMV Type Start End Output Time Lapsed Loss time Delay Responsible Input Time Lost Responsible Remarks
2 3:45 0Hr 25Min 0Hr 22Min 0Hr 03Min 0Hr 10Min
1 0.3 LS 3:45 3:48 3:55 7 Min 3 Min RQ Sup 4 Min RQ Sup
2 0.5 3:55 3:58 4:07 9 Min 3 Min Prod. Supv. 4 Min Prod. Supv.
3 0.18 4:10 4:13 4:16 3 Min 3 Min 3 Min Prod. Supv. 1 Min Prod. Supv.
4 0.5 4:16 4:29 4:35 6 Min 13 Min Prod. Supv. 1 Min Prod. Supv.
5
6

LOSS TIME SUMMARY

Mechanic 0Hr 22Min
Prod. Supv. 0Hr 09Min
RQ Sup 0Hr 04Min
IE

CALCULATION METHOD
Mc MC Setting
MC Mc Setting 1st Bundle MC Setting
Sr Operation SMV Setting Time Lapsed start Responsible Input Time Lost Responsible
Type Start Output Loss time
End Delay

B C D E F G H I J K L M N
Auto pick up from ERP after Data collection either RFID or =IF(H7>0,H =(IF(G7<H6,0 =(IF(F7<H6, =I6-(Bundle size*
Manual Manual
putting new style number Manual 7-G7,0) ,G7-H6))-K7 0,F7-H6)) Operations SMV*2)
Anexes

31