LINE BALANCING MODULEBng n v cn bng chuyn

Content:I. Overview khi qutII. Scope phm viObjective mc tiuComponents of LB Template Ni dung thnh phn ca LBN (cn bng chuyn)V. Procedures th tc

I. OverviewLine Balancing is the process of assigning tasks to workstations in such a way that the workstation have approximately equal time requirements. It is a problem solving tool to simply identify the constraints so as to provide a counter solutions. LB l bng phn cng quy trnh sp xp cng on v thi gian lm vic trn chuyn gn nh nhau. l vn nhn bit mt cch n gin v thi gian d phng It is the simplest form of utilizing resources in workstations thus, attaining the maximum productivity. The aid of line balancing connotes ideal transformation of overall cells performance as a whole. l hnh thc n gin nht tn dng ngun ti nguyn trn trm lm vic v t c nng sut cao. Thay vo LB cn thay i quan nim thnh qu ca ton Cell nh mt khi thng nht.In line balancing concept, one-piece flow and pull production system mainly affect its effectiveness and applications within the boundary of consistency. Meaning, it should be in proper practice at all times. Khi nim LB l tc ng chnh trong h thng sn xut ko v dng 1 dng chy, LB ng dng hiu qu trong chuyn vng chc. C ngha nn p dng thch hp cho mi trng hp.

II. Scope Phm vi From identification of daily demand based on allocated quantity in the sewing line schedule until balancing the line. T s nhn bit hng ngy da trn s lng hng n nh trn chuyn,bng k hoch n bng LB

III. ObjectiveEstablish the effectiveness of line balancing in order to meet the following expectations such as: Lp bng LB v hp v nhng d tnh sau:Utilization of manpower nhn cng x dngDetermine the capacity of the sewing line Xc nh kh nng ca chuynIdentify bottle necks Nhn bit tnh trng nght c chaiTime Utilization thi gian x dngIncrease productivity Tng nng sutIdentify factors that affect cell performance Nhn t lm nh hng thnh qu ca Cell

OLDREVISED

Date ngyLine No. chuynStyle no.s m hngSp no.s SPDaily demand nh mc hng ngyNet available time t.gian x dngTakt time t.gian nh mcLine balancing no.s LBIdeal Operators Cng nhn

Operation no.S cng onOperators name tn C.NMachine type loi myOperation description miu t cng onProcess cycle time t.gian chu k qu trnhCurrent operators C.N hin cProduction rate in seconds Tc sn xut tnh bng giyEnd of the Line rate cui chuyn% utilization t l % s dng

Legend:Automatic updateManual update

Highlights The lowestEOLR Hin th cng on cui thp nhtAutomatically Highlights when cycle time is over the takt time. T ng hin th khc khi vt T.Gian nh mc

Takt time (red line)Operator cycle time in secondsLine Balancing GraphOperators nameTime in seconds

IV. Procedures2. Identify the daily demand and compute for the takt time. Xc nh nhu cu hng ngy v tnh t.gian nh mc3. Get actual cycle time per operator. Ly t.gian chu k tht,cho mi C.N4. Compute for the cycle time of all operators . Tnh t.gian chu k cho tt c C.N 5. Analyze the results. Phn tch kt qu6. Do Line Balancing. Thc hin bng cn bng chuyn7. Monitor cell performance. Gim st kt qu ca chuyn1. Check the sewing line status on the sewing line schedule. Kim tra tnh trng chuyn qua bng quy trnh may

1. Check the sewing line status on the sewing line schedule. Daily target QTY of the line

2. Identify the daily demand and compute for the takt time. Formulas: Takt Time = Daily DemandAvailable TimeTakt Time = 27,000 sec (7.5hrs) 75 pcs/day = 360 secs.

To get actual cycle time per operator: Ly t.gian chu k thc cho mt C.N Time starts from getting the garments and time stops when the garment is placed/give to the next operator. T.gian c tnh bt u ly bn thnh phm cho n khi hon tt cng on v tr v khay ng. Record the cycle time per operator. Get 3 trials of time & get the average cycle time to obtain a realistic time. Example:Average Cycle time will be the basis in recording the CT of the operator in LB report3. Get the cycle time per operator

1st time trial2nd time trial3rd time trialAverage cycle timeOperator 1105 sec117 sec112 sec111 secOperator 285 sec75 sec99 sec86 sec

Record only the time when the operator start getting the cut-parts until finished. Dont record & stop the time if the operator do this following things. - Stand-up & go away from her work area. - Do repair on the operation. - Talking to the other operator. - Other activities which is not part of her operations. 4. Update all other information's on the Line balancing forms & tabulate the data. Operations description Cycle time per operator other information based on the LB template

Additional Formulas:

EOLR (End of line rate) Means an output rate or capacity that your sewing line can achieve basing on the operator highest cycle time.- Check EOLR results if it meets the target daily demand. If lower means that your line will not able achieve the demand at the end of the day.EOLR analysis5. Analyze the results.Make comparison between the sewing line capacity & daily demand based on sewing line schedule

% Utilization Means how well each operators time was utilized according to operation assignment.A.) Check the %utilization of each operator & analyze. 144% means that the operator are fully loaded basing on her CT against the Takt time.B.) if 32 % means only 32 % of the time was utilize based on taktime. So the operator is nothing to do for the rest of the 68 % of the time.% utilization analysis

80% or 196secs is the target time to balance all the operator for downtime occurrence.20% or 49 secs this is the time allowance for downtime occurs on the operator like thread breakage, repair, machine problem & other problem.Takt time 245 secs a time set to meet the daily target demand of the sewing line.C.) If possible let all the operator utilize 80% of the time. Balance the time to 80% of the takt timeTarget balance rate

Takt time245 secs(80% of TT)196 secs80% or 196secs is the target time to balance all the operator to supplement the downtime.20% or 49 secs this is the time allowance for downtime occurs on the operator like thread breakage, repair, machine problem & other problem.Takt time 245 secs a time set to meet the daily target demand of the sewing line.20% for downtimeC.) If possible let all the operator utilize 80% of the time.Target balance rate

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Line Balancing

ESPRINTA VIETNAM - Line Balancing Template

Date4-Aug-08Daily Demand Pcs/Pr110LB No:Ideal Operators

Net Available Time27,000218.86

LINE23Takt Time in Seconds245

Operation No.Operator's NameMachine TypeStyle NO. F8150030-AProcess Cycle Time Sec.Current OperatorsProduction Rate SecondsEOLR / Day = net avail. Time / Production rate% Utilization

SP No. 2008342QB

Operation Description138

Totals4630.0028

245.51nganMHset all cut parts6016045024.44%

245.52thanh3t+snmay got lon nap tui x 3+ gap mieng tui tren188118814476.59%

245.53maisn+sndieu dap tui x 3+dong tui tren +gan dap tui tren+ gap dieu do x2196119613879.85%

245.54sinhsndinh hinh coi tui suon+ rap gan lot tui suon188118814476.59%

245.55nhisnrap suon+ dieu suon179117915172.93%

245.56hiensndieu mieng tui + may bao tui19029528477.41%

245.57hoasnke may dap tui tt duoi+luot coi tui duoi+ld- dh bam mo mieng tui duoi195119513879.44%

245.58thanhsnbam goc mieng tui duoi+khoa luoi ga+ dieu mieng tui duoi191119114177.81%

245.59hasn+bkld- dong nap tui duoi+dong bo189118914377.00%

245.510hasmld- dong nut179117915172.93%

245.511nhosnrap phoi suon sau107110725243.59%

245.512hoai3t+sndieu phoi suon sau+ vs tui suon+ gan day cau171117115869.67%

245.513vuonsntra tay+ gan day cau137113719755.81%

245.514vinhsn+gmdieu tay+ dieu day vien tay190119014277.41%

245.515tinh3t+snld- rap suon+ gan day cau+vs suon196119613879.85%

245.516hogm+dnmay day treo lung+ may day vien lung141114119157.44%

245.517trinhsntra co+ tra nep do dk190119014277.41%

245.518xuansnld- tra dk+ tra nep do dk158115817164.37%

245.519vandnld- ke dieu nep che119111922748.48%

245.520huesnld- gan nham dk180118015073.33%

245.521hoasn+snld- tra co lot + luot lot tui+ dieu nhan ts lot+ khoa 2 dau lai170117015969.26%

245.522quysndup dk lot187118714476.19%

245.523hue(a)snld- khoa co + gan toan bo day cau188118814476.59%

245.524vansndieu dk tp vong qua co194119413979.04%

245.525huyensnmay lai tp195119513879.44%

245.526huongsnmay lai ao176117615371.70%

245.527huongsnPacking176117615371.70%

245.528huongsnPressing176117615371.70%

2007

Graph

Analysis:

AnalysisCorrective Action

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ideal operator It is the target or needed operator to perform the whole operations considering all are 100% balance basing on the cycle time against the takt time. - Reduce manpower if possible to increase sewing line efficiency.

Ideal operator analysis

Identify all the cycle time which is above & below the takt time. If all operator/operations are below takt time identify the 3highest & lowest cycle time & balance it.Identify & evaluate the highest & lowest cycle time6. Do Line Balancing. Thc hin bng cn bng chuyn

B.) Check the proper handling, movement & degrees or number of operations assigned to the operator.C.) Check the machines used, threads, skills of the operator, machine foot & attachment.Evaluate the operations/activity of the operator

a.) Sub-divide and give the operations to the other operators whose cycle time is lesser than the takt time.b.) Have additional operator if the operations cant be divided. C.) Check if there are possibility to reduce the manpower to increase efficiency performance.Discussion with the line leader / technical personnel

a.) Get the cycle time again to those operator made changes after line balancing.b.) Check other highest operations & continuously do the line balancing.Conduct time study (Re-time study)

a.) Check the hourly output trend if meet the target or not, then identify wheres the problem & make improvements on it. b.) Check the operator as well if they are performing well in terms of sewing speed.C.) Discuss with the cell manager on other concerns in the sewing line that affect the line balancing/performance of the line. Monitor the Output Trend

Monitor cell performance through output, RFT, quality, and downtime. Quan st tnh trng Cell thng qua s.phm ,bn thnh phm(ang trn cell) v t.gian cht.8. Monitor Cell Performance Quan st tnh trng Cell7. Update & post the Information in the line - Line Mapping - Line Balancing template & graph - Process flow chart