Line Balance Optimisation (LBO) Overview

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Introduction

What is “LBO”?

“It is the process of optimising line performance through the effective use of automation and control

philosophies”

Where is it applicable?

On any automated, multi-machine, production line where equipment speeds can be varied and spare capacity exists within the conveyor / transport system

The Basic RulesThere are three very simple rules to follow when considering Line Control:

1. Maintain the Critical Machine in a running state, ideally at its optimum speed

2. If upstream or downstream equipment fails, maintain the Critical machine in a running state for as long as possible

3. If the Critical Machine has stopped, restart it as quickly as possible

V-Curve Explained

Production lines are regularly designed and setup by using the practice of applying a “V-curve”.In reality, this more often resembles a tick () in shape.

Critical machine

Filler30,000 uph

Packer36,000 uph

Labeller33,000 uph

Depalletiser33,000 uph

Palletiser40,000 uph

Normally Full conveyors

Normally Empty conveyors

Example Production Line:(generic bottling ine shown)

Uph = Units per Hour

Vision of Perfect FlowTo set us a target to aim for, let us envisage what “perfect flow” would look like:

• All equipment on the line runs in automatic without any manual intervention

• During normal running conditions, the line speed is matched to that of the critical machine

• All equipment stops are clearly indicated and identifiable• Minor stops to upstream and downstream equipment does not affect

the critical machine• Major stops affect the critical machine for the minimum period• The critical machine restarts almost instantaneously after a stoppage

Perfect Flow, the Multiple Hour-glass Model

Explanation of Model:

• Imagine a number of hour-glasses stacked on top of each other• Each “bubble” represents a section of conveyor• The “holes” between bubbles represents the equipment on the

line• The smallest hole represents the critical machine• The size of the hole represents the max speed of the equipment• The coloured (orange) area represents product & its flow• (The conveyors are all shown same size though in reality are

likely to vary)

• Attempting to run downstream equipment faster than the critical machine results in self-starving, “hunting” and equipment start-stopping.

Perfect Flow, the Multiple Hour-glass Model

Normal Running Machine Stopped

Stop

Machine Restarted

Restart