Line Balancing
Overall view:
It is an art of distributing the work equally. It is quite a difficult job. While
designing the lay out and distributing the work one has to ask many
questions to himself.
Line Balancing.
• Determine: -
IS the job is necessary.
IS it being performed in the right place?
IS it at the right time?
IS it by the right operator?
• Motion Economy.
If the operation satisfies all the above criteria, the next
Stage is to improve the method being used
• Standard Operation.
Then record the best operating method that can be
Put into effect right now.
• Continuous Improvement.
All of the above should be periodically reviewed to
Improve Quality, Safety and Efficiency.
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Main areas of waste, which should be minimized in a line balance:
• Idle Time.
Work should be distributed so that each worker is 100% occupied.
Surplus time should be concentrated in one worker.
• Ineffective Working Arrangement.
If the product is large, should work on different sides of it be done by
the same operator, or should it be split?
How much unnecessary traveling is involved?
• The Job Itself.
Does this operation add any value to the product?
Motion Economy
The Four Principles of Motion Economy:
1. Reduce the Number of Motions.
Eliminate or reduce the number of motions.
E.g. slip-on shoes save time.
2. Perform Motions Simultaneously.
Design improvements in the methods and tools, which allow both hands to
be used at the same time.
E.g. driving a car - using both hands and feet.
3. Shorten Motion Distances
Reduce - walking, reaching, stretching, squatting and turning, etc.
e.g. TV remote controls or moving storage racking closer.
4. Make Motion Easier.
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Work should be smooth and rhythmical, reduce fatigue and promote
safety.
E.g. using counterbalance hoist to help the use of heavy tools.
Use these four principles to analyze and improve the following three areas:
A - Use of the human body.
Where possible:
- Both hands should start and finish the operation at the same time.
- Reduce idle time for either or both hands, except at times of rest.
- Arm motions should be symmetrical, in opposite directions and performed
simultaneously.
- Employ curved movements during the operation, rather than straight-line
motions involving sharp changes in direction.
- Employ rhythmical standard operation, so one assignment naturally
follows on to the next (position of parts).
- Ensure a similar focal point for tools, materials, etc. to reduce head
movements and eyestrain.
B. Arrangement of the work place.
Where possible
- Use fixed positions for tooling and parts to allow habits to form easily.
- Use gravity feeding to ensure a common pickup point.
- Position parts, materials and tools to enable sequential use.
- Use ejector systems or drop deliveries, so the operator has minimal
effort to pass on parts to the next operation.
- Benches and chairs should be at the correct working height to avoid
interrupted motions.
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- All equipment should be within the maximum work area
C. - Design of tools and equipment.
Where possible
- Eliminate the need to use one hand purely to hold a part by using jigs.
- Use combination tools (back to back benches).
- Use counterbalances on heavy tooling.
- Ensure handles on tools are designed to use maximum hand contact.
- Place tooling in the most convenient positions, to eliminate excessive
body movements.
- Where two operators are fitting the same part to their respective sides of
a large product, (e.g. wheels on a car assembly line), separate part
supplies should be used.
- Tools should be placed to enable immediate use, without having to turn,
lift or alter their position beforehand.
- Provide chutes for access of parts, and components in/out of the
workplace.
D:- Finished work should
- Be easily passed to the next station.
- Be simultaneously released, as the next part is being obtained.
- Be easily placed so the next operator can easily collect it, ready for
the next assignment.
If eye selection is required, position the parts/tools to minimize head
movements.
Ensure the parts container(s) and/or supply method is in proportion to
the part.
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