Line Balancing - Amila Wickramaseara
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Production Line Balancing Productivity Improvement Project
Objective
To educate production related staff on production line balancing
Production Line Status
Ø Unbalanced status Ø Balanced status
Overview Ø Disadvantages due to improper line balancing Ø Factors effected for unbalancing a production line Ø Steps to be followed - Line balancing Ø Week Points to be improved Ø Expected skill inventory after training Ø Maintaining the proper line balancing
Disadvantages Improper line balancing Ø Difficult to meet delivery date Ø Under utilization of workers’ capacity Ø Wastages Ø Space Ø Electricity Ø Extra payments Ø Extra workload
Ø Creating problems
Higher Absentee ism
Higher Defective Percentage Poor Team Work
Higher M/C Break Down
Ignoranc e Higher Labor Turn Over
Poor Data Recording & Analysis Unskilled Workers
Steps to be followed - Line balancing 1. Daily Production Target
Steps to be followed - Line balancing 2. Actual Available Time per operator per day
Spent Time Per Day
Attendance Rate
Efficiency
480 min
346min
Steps to be followed… 3. Balance Time per operator per day Target output per day = 770 Actual Available Time Per Operator Per Day = 346 minutes
Steps to be followed… 3. Preparing the analysis sheet ( For Theoretical Manning Level – TML ) No
1 2 3 4 5 6
Operation
Back York O/L Back York Out Line Back Rise O/L Back Rise O/L Out Line Back Pocket Hem Back Pocket Attach
Machine Type
SMV
Balance Time
Calculation
TML
O/L D/N/L/S O/L D/N/L/S D/N/L/S D/N/L/S
0.47 0.43 0.39 0.41 0.46 0.95
0.45 0.45 0.45 0.45 0.45 0.45
0.47 / 0.45 0.43 / 0.45 0.39 / 0.45 0.41 / 0.45 0.46 / 0.45 0.95 / 0.12
1.05 0.96 0.87 0.91 1.03 2.12
TML – No. of mans, Perform in 100 rate
Steps to be followed… 3. Preparing the skill inventory ( Actual Manning Level - AML - Performance) Name Manosha Lalani Sunethra Dayani Nadeeka Sanjeewani Sriyani Bimali Indika Indrani Chandrika Manjula
E.P.F.NO 945 449 330 772 957 969 357 136 288 156 999 171
Pocket Hem
Pocket Side Seam F/R rise Attach
SNLS 0.90
0.95
OL 0.85
Pkt bag
F/R rise Pkt Out line
F/R waist covering
Bow Bow Check Marking Marking
DNLS
H/P
0.90
0.75 0.75
0.65
0.85 0.90 0.70 0.70 0.85 0.70 0.65 0.90
0.80 0.75 0.80
Steps to be followed… 4. Matching AML values with TML values
Balance Time 0.45 0.45 0.45 0.45 0.45 0.45 0.45
TML 1.05 0.96 0.87 0.91 0.74 0.47 1.52
AMLS 0.00 0.69 0.84 0.76 0.8, 0.93 0.74 0.8, 0.85,0.78, 0.83
Total AMLS
AMLS- TML
0.00 0.69 0.84 0.00 0.8 0.74 1.58
-1.05 -0.27 -0.03 -0.91 0.06 0.27 0.06
Comment Not Available Less Capacity Well fitted Used Well fitted Over Capacity Many Operators
Steps to be followed…
s n io t a r e p O
4. Line Balancing Graph 43 40 37 34 31 28 25 22 19 16 13 10 7 4 1
Unavailab le
-1.50
-1.00
-0.50
0.00
Over Capaci ty
Merge Point 0.50
ManningLevel Difference
1.00
Week Points to be improved Ø Improper Layout Ø Poor handling Ø Improper work place arrangement Ø Inadequate machine adjustments
Expected skill inventory after training
NERANJALA GEETHAMALA INDIKA YAMUNA SUJEEVE DEEPIKA SHIRANI INOKA DAYANI DAMAYANTHI SUGANDI UDENI NISANSALA SHANIKA PRIYANKA
70 75
75
70 70 75 60
82 70
65 80 80 80
75 70 70 75 70 80 80 75 65 80 60 90 85 80 100 80 80 80
90
70 80 80 80
LINING SHELLATT
80
60 90 90 75 75 80
NECKCLOSE
TSZIPPER
ZIPPERCLOSE
COLLERCLOSE
WBCLOSE
70 75 85 85 80
75 85 75 80 60
80 65
80 95 75 100 85 65 90 95 80 70
TSCUFF
ZIPPERATT
TSWBTOP
80 85
80 75 70 75 100 75 75 70 65 65 65 60 80 65 60 70 95 80 100 95 75 85 80 90 65 90 90 80 80 50 75 80 80 70 90
TSSIDE SEAM
FLYBOXATT WITHZIPPER
TSBTM HEM
WBATT
FLAPATT & TSFLAP
CUT PKT OUT LINE
WELT ATT
BACKPKTATT
CARGO PKTATT
TACKPKT BAG
PKT BAG ATTTO FRONT
MAKE 'J'
FLYATT TO FRONT
969 971 1362 1458 1469 1619 1773 1823 2056 2090 2144 2414 2486 2819 2913
JKT SNLS
FACING ATT
EPFNO
A A A A A B A A+ A A+ B A+ C B A+
PANT
OPERATORNAME
GRADE
O/PTYPE M/CTYPE
75 70 80 80
How to sustain an improved Line Ø Update the skill inventory style wise Ø Plan the operator training program by means of the updated skill inventory Ø Follow the correct line balancing method Ø Eliminate factors affected to unbalance a production line Ø Higher M/C break down
Ø Control KPI values related to production line Ø Absenteeism Ø Labor turn over
Summary Ø Correct production line balancing method Ø Guide to schedule the operator training program Ø How to maintain a balanced production line
THANK YOU
Objective
To educate production related staff on production line balancing
Production Line Status
Ø Unbalanced status Ø Balanced status
Overview Ø Disadvantages due to improper line balancing Ø Factors effected for unbalancing a production line Ø Steps to be followed - Line balancing Ø Week Points to be improved Ø Expected skill inventory after training Ø Maintaining the proper line balancing
Disadvantages Improper line balancing Ø Difficult to meet delivery date Ø Under utilization of workers’ capacity Ø Wastages Ø Space Ø Electricity Ø Extra payments Ø Extra workload
Ø Creating problems
Higher Absentee ism
Higher Defective Percentage Poor Team Work
Higher M/C Break Down
Ignoranc e Higher Labor Turn Over
Poor Data Recording & Analysis Unskilled Workers
Steps to be followed - Line balancing 1. Daily Production Target
Steps to be followed - Line balancing 2. Actual Available Time per operator per day
Spent Time Per Day
Attendance Rate
Efficiency
480 min
346min
Steps to be followed… 3. Balance Time per operator per day Target output per day = 770 Actual Available Time Per Operator Per Day = 346 minutes
Steps to be followed… 3. Preparing the analysis sheet ( For Theoretical Manning Level – TML ) No
1 2 3 4 5 6
Operation
Back York O/L Back York Out Line Back Rise O/L Back Rise O/L Out Line Back Pocket Hem Back Pocket Attach
Machine Type
SMV
Balance Time
Calculation
TML
O/L D/N/L/S O/L D/N/L/S D/N/L/S D/N/L/S
0.47 0.43 0.39 0.41 0.46 0.95
0.45 0.45 0.45 0.45 0.45 0.45
0.47 / 0.45 0.43 / 0.45 0.39 / 0.45 0.41 / 0.45 0.46 / 0.45 0.95 / 0.12
1.05 0.96 0.87 0.91 1.03 2.12
TML – No. of mans, Perform in 100 rate
Steps to be followed… 3. Preparing the skill inventory ( Actual Manning Level - AML - Performance) Name Manosha Lalani Sunethra Dayani Nadeeka Sanjeewani Sriyani Bimali Indika Indrani Chandrika Manjula
E.P.F.NO 945 449 330 772 957 969 357 136 288 156 999 171
Pocket Hem
Pocket Side Seam F/R rise Attach
SNLS 0.90
0.95
OL 0.85
Pkt bag
F/R rise Pkt Out line
F/R waist covering
Bow Bow Check Marking Marking
DNLS
H/P
0.90
0.75 0.75
0.65
0.85 0.90 0.70 0.70 0.85 0.70 0.65 0.90
0.80 0.75 0.80
Steps to be followed… 4. Matching AML values with TML values
Balance Time 0.45 0.45 0.45 0.45 0.45 0.45 0.45
TML 1.05 0.96 0.87 0.91 0.74 0.47 1.52
AMLS 0.00 0.69 0.84 0.76 0.8, 0.93 0.74 0.8, 0.85,0.78, 0.83
Total AMLS
AMLS- TML
0.00 0.69 0.84 0.00 0.8 0.74 1.58
-1.05 -0.27 -0.03 -0.91 0.06 0.27 0.06
Comment Not Available Less Capacity Well fitted Used Well fitted Over Capacity Many Operators
Steps to be followed…
s n io t a r e p O
4. Line Balancing Graph 43 40 37 34 31 28 25 22 19 16 13 10 7 4 1
Unavailab le
-1.50
-1.00
-0.50
0.00
Over Capaci ty
Merge Point 0.50
ManningLevel Difference
1.00
Week Points to be improved Ø Improper Layout Ø Poor handling Ø Improper work place arrangement Ø Inadequate machine adjustments
Expected skill inventory after training
NERANJALA GEETHAMALA INDIKA YAMUNA SUJEEVE DEEPIKA SHIRANI INOKA DAYANI DAMAYANTHI SUGANDI UDENI NISANSALA SHANIKA PRIYANKA
70 75
75
70 70 75 60
82 70
65 80 80 80
75 70 70 75 70 80 80 75 65 80 60 90 85 80 100 80 80 80
90
70 80 80 80
LINING SHELLATT
80
60 90 90 75 75 80
NECKCLOSE
TSZIPPER
ZIPPERCLOSE
COLLERCLOSE
WBCLOSE
70 75 85 85 80
75 85 75 80 60
80 65
80 95 75 100 85 65 90 95 80 70
TSCUFF
ZIPPERATT
TSWBTOP
80 85
80 75 70 75 100 75 75 70 65 65 65 60 80 65 60 70 95 80 100 95 75 85 80 90 65 90 90 80 80 50 75 80 80 70 90
TSSIDE SEAM
FLYBOXATT WITHZIPPER
TSBTM HEM
WBATT
FLAPATT & TSFLAP
CUT PKT OUT LINE
WELT ATT
BACKPKTATT
CARGO PKTATT
TACKPKT BAG
PKT BAG ATTTO FRONT
MAKE 'J'
FLYATT TO FRONT
969 971 1362 1458 1469 1619 1773 1823 2056 2090 2144 2414 2486 2819 2913
JKT SNLS
FACING ATT
EPFNO
A A A A A B A A+ A A+ B A+ C B A+
PANT
OPERATORNAME
GRADE
O/PTYPE M/CTYPE
75 70 80 80
How to sustain an improved Line Ø Update the skill inventory style wise Ø Plan the operator training program by means of the updated skill inventory Ø Follow the correct line balancing method Ø Eliminate factors affected to unbalance a production line Ø Higher M/C break down
Ø Control KPI values related to production line Ø Absenteeism Ø Labor turn over
Summary Ø Correct production line balancing method Ø Guide to schedule the operator training program Ø How to maintain a balanced production line
THANK YOU
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