How do we balance workstations ?
Balancing workstations in a production line is used to improve technological flow by reducing worthless activities. The balancing of the line consists in distributing the work as evenly as possible between the stations.
The reference time for balancing production operations is the tact time calculated based on the customer's order and available capacity.
This type of project is carried out in two stages: evaluating the current situation and preparing & implementing the future situation.
For the initial state, the adopted methodology includes the calculation of the cycle time of the process steps according to the work instructions on the stations.
In general, in the time study, there are 3 steps: Analysis, measurement and synthesis.
The analysis begins with the announcement of the operators about the activity and its purpose. It is checked if the equipment and tools used are in parameters and work according to the norms, especially those that involve the adjustment of the parameters that influence the speed.
All settings must be made in advance. Materials are provided at the station under series production conditions.
The measurement is done with the timer and the data are written in the data collection sheet (sometimes it is specific. Ex. REFA form) The timing and recording of the data follows.
Synthesis involves analyzing data using visual techniques, such as graphs or the Yamazumi diagram. The Yamazumi diagram is a machine and operator cycle visualization tool to evaluate performance. It is also a good indicator of the variation between workstations doing the same thing. Variations (mura in Japanese) result in moulting or waste in the form of delays and excess inventory.
Depending on the cycle times that resulted from the measurements, we have to balance the times between stations, after removing the actions without added value (NVA). Once the changes are made, we standardize by updating the work instructions and re-verify the effectiveness of the actions taken.
Balancing workstation loads leads to:
The reference time for balancing production operations is the tact time calculated based on the customer's order and available capacity.
This type of project is carried out in two stages: evaluating the current situation and preparing & implementing the future situation.
For the initial state, the adopted methodology includes the calculation of the cycle time of the process steps according to the work instructions on the stations.
In general, in the time study, there are 3 steps: Analysis, measurement and synthesis.
The analysis begins with the announcement of the operators about the activity and its purpose. It is checked if the equipment and tools used are in parameters and work according to the norms, especially those that involve the adjustment of the parameters that influence the speed.
All settings must be made in advance. Materials are provided at the station under series production conditions.
The measurement is done with the timer and the data are written in the data collection sheet (sometimes it is specific. Ex. REFA form) The timing and recording of the data follows.
Synthesis involves analyzing data using visual techniques, such as graphs or the Yamazumi diagram. The Yamazumi diagram is a machine and operator cycle visualization tool to evaluate performance. It is also a good indicator of the variation between workstations doing the same thing. Variations (mura in Japanese) result in moulting or waste in the form of delays and excess inventory.
Depending on the cycle times that resulted from the measurements, we have to balance the times between stations, after removing the actions without added value (NVA). Once the changes are made, we standardize by updating the work instructions and re-verify the effectiveness of the actions taken.
Balancing workstation loads leads to:
- Decreased waste
- Increasing ergonomics at work
- Increasing the Efficiency and therefore the Production Capacity (without increasing the resources consumed - people or machines)
- Increasing profits by lowering costs
