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Adidas - Line Balancing 1

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33 views14 pages

Adidas - Line Balancing 1

Uploaded by

allahnawazksadozai
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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019

LINE
BALANCING
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
LINE BALANCING

- Way of adjusting each operation’s loading to make each operation’s time value almost the same
- key driver for a good production efficiency
- based on workers cycle time / the average GSD SMV for the style

Prior to style change over, a line balance plan is used to determine:


 Machine requirement – number of units and machine type
 Operator
o Number of operators
o Required skill level
 Sequence of operations in the production line

LBR = ___________Total Cycle Time__________ x 100%


Number of workstations * Bottleneck CT
PRACTICE:

Your production line have 3 operations, below are details, how to calculate the line
balancing rate?

operation Cycle time (Mins) Number of workers

A 2 1
B 5 2
C 2 1
BOTTLENECK / CONSTRAINT
Why balancing is important in setting up the line:
To eliminate excessive work in progress (WIP) or bottlenecks

What is Bottleneck?
- operators completing sewing operations of higher SMV’s, compared to all other
operators
- holds up the work for operators further down the line causing production stoppages
BOTTLENECK / CONSTRAINT
How to determine bottleneck operation?
- through WIP (Work In Progress)
- cycle time check
What does WIP do?
• Hides the problem
• Disable quality control
• Limits labor utilization
5 FOCUSING STEPS

7
HOW TO ANALYZE THE LINE BALANCE
• Production output?
• SMV?
• Stop watch to check cycle time

8
LINE BALANCING

Redistribute the work in the most “waste-


free” manner

Improve the
operations
which are far
from takt time
or shows to
create potential
bottleneck

9
LINE BALANCING PROCESS

TIME
CYCLETIME
CYCLE
 Share Method
 Rearrange bottleneck operation
 OPERATOR 1 2 3 4 5
OPERATOR 1 2 3 4 5

CYCLE
OPERATOR
OPERATOR TIME
CYCLETIME 11 22 33 44 55

10
LINE BALANCING PROCESS

Optr 4

TIME
CYCLETIME
CYCLE
Optr 3
 Reduce cycle time by
additional/shared operator
OPERATOR
OPERATOR 1
1 2
2 3&
34 5
4 6
5

 Separate & Eliminate operation


elements

TIME
CYCLETIME
CYCLE
OPERATOR
OPERATOR 11 22 23 34 45

11
LINE BALANCING EXAMPLE

12
LINE BALANCING PROCESS
Build Sewer Database:
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
THANK
YOU

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