Download - Production Balancing
-
7/30/2019 Production Balancing
1/44
Production Balancing
The phrase that spreads fear into
managers and supervisors& students?
-
7/30/2019 Production Balancing
2/44
Production Balancing
The views of someone whohas:
-been there
-done that
-got the T-shirt
-been driven crazy by it all
-
7/30/2019 Production Balancing
3/44
Factory watch
Production targets not being met
Production targets being met exactly
Operators sitting idle Operators complaining about being
constantly moved between jobs
Large build up of work in progress No work in progress
-
7/30/2019 Production Balancing
4/44
YES
You have a production
balancing and productionmanagement problem!
-
7/30/2019 Production Balancing
5/44
Production Balancing -A Definition
Ensuring that input = output on all
operations and work sections. X
Ensuring that input= output on alloperations and work sections and that all
operations and operators have the
opportunity to work to their maximum
potential.
-
7/30/2019 Production Balancing
6/44
Water tanks
a Each tank has its own
inlet & outlet valves
Valves are difficult to
open to exactlycorrect settings
Each tank contains an
amount of water
OP 1
OP 2
OP 3
OP 1
-
7/30/2019 Production Balancing
7/44
Water tanks - operations
Each operation has a different labour
content. S.A.M. S.M.V.
Every operator works at a different pace.
Many operators work inconsistently.
Machines break quality problems -
absence
-
7/30/2019 Production Balancing
8/44
Production Balancing
Initial Balance - planning
skills matrix
operation list
SMVs Running the section
initial balance
skills matrixW.I.P. levels
Live output data
-
7/30/2019 Production Balancing
9/44
Operator information
What tasks can
they do?
How well can they
do them?
Factual-numerical
Based on ability-not previous output
Hold on a skills
matrix
Recent not old
history
Potential output
Performance/
garments per hour
-
7/30/2019 Production Balancing
10/44
Operator performance
Do not rely only on historical information.
Circumstances may have affected
performance e.g. lack of work
Find out potential performance from
cycle timing and come to decision about
performance level to be used.
-
7/30/2019 Production Balancing
11/44
Potential performance
Find cycle time
Compare with basic time.
Example SMV = 0.60
Allowances = 20%
Bundle handling allowance = 0.02 Average cycle time = 0.70
-
7/30/2019 Production Balancing
12/44
Potential performance
Basic time = (smv bundling) -allowances = (0.60-0.02) 20% = 0.464
Basic time = 0.464
Cycle time = 0.70
Potential Performance = basic timex 100
cycle time
= 0.464 = 66%
0.70
-
7/30/2019 Production Balancing
13/44
Potential performance
SMV = 0.60
Potential performance = 66%
@ 100% output per hour = 60/0.60 = 100 Potential performance = 66% therefore
potential output per hour = 100 x 66%
= 66 pieces per hour
-
7/30/2019 Production Balancing
14/44
Potential performance
Using cycle time and potential
performance is absolutely essential in
effective balancing/setting up of modular
manufacturing teams.
-
7/30/2019 Production Balancing
15/44
Potential performance and output
SMV = 0.36
Bundling 0.015
Allowances 18%
Average cycle time =
0.25
Potential
performance? Potential hourly
output?
SMV = 0.45
Bundling 0.02
Allowances 15%
Average cycle time =
0.40
Potential
performance? Potential hourly
output?
-
7/30/2019 Production Balancing
16/44
Potential performance and output
0.36 0.015 = 0.345
0.345 18%of SMV
= 0.283 basic time
Cycle = 0.25
P.perf. = basic =0.283
cycle 0.25
= 113%
0.45-0.02 = 0.43
0.43 15%of SMV
= 0.366 basic time
Cycle = 0.40
= basic = 0.366
cycle 0.40
= 91%
-
7/30/2019 Production Balancing
17/44
Skills Matrix
Operator/job title Elasticate Backs yokes lace t/s front sh & slvs bind neck slvs in hem t/s hem
Doreen 75 75
Duresha 100 90 90 90
Geetha 120 100 120 120
Indrani 100 75 100
Iromi 100 75
Jeevani 100 100 100 100
Mangalika 75 75 65
Neetha 120 120 120 120
Nirosha 75 100
Pushpa 100 50 100
Thushanti
Shirani
50
25
50
75
50
75
75
50
75
50
50
75
75
50
50
75
50
25
75
50
-
7/30/2019 Production Balancing
18/44
Skills Matrix
Supervisors will tell you a skills matrix isnot necessary they know what peoplecan do!
Problem. What is in their head is notavailable to others!
What if an operator changes section or the
supervisor changes section or leaves. People forget things! Do not depend upon
the operator to tell you what the can do.
-
7/30/2019 Production Balancing
19/44
Skills matrix
A skills matrix gives you a picture and picturesare easy to understand.
At a glance you can see cover, number of
operators that can do an operation You can see how multi-skilled each operator is.
Helps with multi-skilling plans
It is of limited value if held in the computer in
Industrial engineering. Keep it up to date- people leave or learn new
operations, performances change.
-
7/30/2019 Production Balancing
20/44
Initial balance
What is Shirani &Thushantis role in the section?
NEVER, NEVER, EVER include the floater in theinitial balance
When they are included in the initial balancethey are not available to perform floating jobsand cease to be a floater
BEWARE: Supervisors will use floaters as
repair hands, helper, trainer, sample hand orleave them where they are useful and doing agood job.
-
7/30/2019 Production Balancing
21/44
Floater calculation
Theory:
Number of operators in section = 30
Average absence = 8%
Floaters cover absence therefore 30 x 8%= 2.4 people missing at any time.
Floaters are not specialists and will usually
work at a lesser rate than regular operator,say 66% therefore 2.4/0.66 = 3.6 = 4needed
-
7/30/2019 Production Balancing
22/44
Floater calculation
Practice
Sufficient floaters are never allocated and
the supervisor has to work with what she
has got.
Usually an inadequate floater supply
mixed with a few operators that are partly
multi-skilled.
-
7/30/2019 Production Balancing
23/44
Operation list
1. Elasticate attach lace elasticator 0.70
& elastic to sleeves
2. Join two back seams 2 needle o/lock 1.00
3. Attach front & back yokes 2 needle o/lock /frill 1.20
4. Attach lace to front yoke L/S Diff feed 1.005. L/s yokes and topstitch 2 needle L/S 1.00
sides to hold
6. Join shoulder& sleeve seams 2 needle o/lock 1.10
7. Attach binding, tab & lace to neck L/S Diff feed 0.708. Attach sleeves 2 needle o/lock diff 1.40
9. Whip hem Cover stitch 0.90
10. Top sew neck and two sleeves Lockstitch 1.00
-
7/30/2019 Production Balancing
24/44
Initial balance
We now know operations and sequence
Machines & SMVs
From skills matrix, what operations eachoperator can do and at what performance
level
We can know allocate people to tasks
complete the initial balance
-
7/30/2019 Production Balancing
25/44
Initial Balance
Op. Number S.M.V. standard operator machine exp. Perf expected spare time garments
output type % per hour
1.elasticate 0.70 86
2.back seam 1.00 60
3.yokes 1.20 50
4.lace 1.00 60
5.t/s front 1.00 60
6. sh & slvs 1.10 55
7. bind neck 0.70 86
8.slvs in 1.40 43
9. hem 0.90 67
10.t/s neck 1.00 60
-
7/30/2019 Production Balancing
26/44
Initial Balance- 60 hour
Op. Number S.M.V. standard operator machine exp. Perf expected spare time garments
output type % per hour
1.elasticate 0.70 86 Doreen 75 64 +4
2.back seam 1.00 60
3.yokes 1.20 50
4.lace 1.00 60
5.t/s front 1.00 60
6. sh & slvs 1.10 55
7. bind neck 0.70 86
8.slvs in 1.40 43
9. hem 0.90 67
10.t/s neck 1.00 60
-
7/30/2019 Production Balancing
27/44
Initial Balance
Op. Number S.M.V. standard operator machine exp. Perf expected spare time garments
output type % per hour
1.elasticate 0.70 86 Doreen elasticator 75 64 0.07 4
2.back seam 1.00 60 Duresha 2n o/l 100 60 0.00 0
3.yokes 1.20 50 Geetha o/l frill 120 60 0.00 0
4.lace 1.00 60 Indrani l/s diff 100 60 0.00 0
5.t/s front 1.00 60 Iromi 2n o/l 100 60 0.00 0
6. sh & slvs 1.10 55 Jeevani 2n o/l 100 55 -0.10 -5
7. bind neck 0.70 86 Mangalika l/s diff 75 64 0.07 4
8.slvs in 1.40 43 Neetha 2n o/l diff 120 51 -0.17 -9
9. hem 0.90 67 Nirosha hemmer 100 67 0.10 7
10.t/s neck 1.00 60 Pushpa l/s 100 60 0.00 0
-
7/30/2019 Production Balancing
28/44
Initial Balance
A perfect balance is not possible unlessevery operation has the same workcontent (SMV) and every operator works
at the same performance. (this can onlybe achieved by restricting work supply tothe lowest operation output). Whatefficiency?
Be aware of potential imbalances
One of the reasons people like modular
-
7/30/2019 Production Balancing
29/44
Section summary
High performing operators-average 99%
Op. 8. sleeve attach is bottle-neck with 51 perhour only despite high performing operator.
If traditional approach is taken and section isbalanced to lowest operation then section underideal circumstances will never achieve higherthan 83% efficiency
Not perfect but no balance will beit ismanageable if we know about it and monitor thesection
-
7/30/2019 Production Balancing
30/44
Hourly target why 60 ?
SMV = 10 per garment
10 operators
Average efficiency of section is 100% No need to factor in absence as sufficient
floater cover.
8% absence average = 0.8 (1) personabsent at ay time. floaters work at lesser
rate and 2 available.
-
7/30/2019 Production Balancing
31/44
Hourly target why 60 ?
10 operators = 600 attended minutes
available in one hour.
600/smv of 10 = 60 per hour.
IF floater cover we not available we would
have needed to reduce target by 8% for
absence. 60 8% = 55 per hour.
-
7/30/2019 Production Balancing
32/44
Running the line
2 things can be guaranteed about a plan
(initial balance)
It will immediately go out of date
It will immediately go wrong.
IT is a starting point
You need to manage people and WIP(Work-in-progress) to make the line work
-
7/30/2019 Production Balancing
33/44
Running the line. Regular checks
Input to every operation
Output from every operation
Work-inprogress levels
1 2 3
-
7/30/2019 Production Balancing
34/44
Running the line
Section: 1. Supervisor: Raveen
Operation Manning 8.00 TO 10.00 10.00 TO 12.00
W.I.P. INPUT OUTPUT W.I.P INPUT OUTPUT W.I.P
1. elasticate Doreen 48 128 128 48
2. Back seams Duresha 48 128
3. front yoke Geetha 484.Lace to yoke Indrani 48
5. L/s yoke Iromi 48
6. Shoulder &
slv smsJeevani 48
7 lace to neck Mangalika 488 Attach sleeves Neetha 48
9. Hem Nirosha 48
10. Top sew Pushpa 48
-
7/30/2019 Production Balancing
35/44
Running the line
Section: 1. Supervisor: Raveen
Operation Manning 1.00 TO 3.00 3.00 TO 5.00
W.I.P. INPUT OUTPUT W.I.P INPUT OUTPUT W.I.P
1. elasticate Doreen 48
2. Back seams Duresha
3. front yoke Geetha
4.Lace to yoke Indrani
5. L/s yoke Iromi
6. Shoulder &
slv smsJeevani
7 lace to neck Mangalika
8 Attach sleeves Neetha
9. Hem Nirosha
10. Top sew Pushpa
-
7/30/2019 Production Balancing
36/44
Running the line
Every operator works to their potential as
shown on the skills matrix.
Iromi is absent.
Factory rules state that no operator
(including floaters) can be moved for less
than one hour and can only be moved in
whole hours.
-
7/30/2019 Production Balancing
37/44
Exercise summary
There were multi-skilled operators
available.
The section was reasonably well
balanced.
Floater cover was available.
WIP was available.
-
7/30/2019 Production Balancing
38/44
Line Balancing
Welcome to the real
world.
An actual example
from a real factory.
-
7/30/2019 Production Balancing
39/44
Operation list standard 5 pocket
jean Fronts sectionOperation M/C S.M.V. @100%Serge front 3 thread o/lock 0.130 450
Attach zipper S/NL/S 0.400 150
Run stitch pockets S/N L/S 0.370 161
(bags to fronts)
Topsew front pkts D/N L/S 0.410 147Secure pkts at sides& waist S/N L/S 0.458 131
J stitch fly D/N L/S ubt 0.340 176
Run stitch front to Secure S/N L/S ubt 0.260 232
Topsew front seam D/N L/S ubt 0.250 240
Join crotch D/N L/S ubt 0.290 205Bartack pkts Bartack 0.170 360
Front sub total.. 3.278
Skill i t F t ti
-
7/30/2019 Production Balancing
40/44
Skills inventory. Fronts section
Operator/job title Sergefront
Attach
Flly &zipper Run pkt Topsew Secure J Runstitch topsew crotch bartack
Huda 100
Sabreen 120
Shadia 112
Aydaa 100
Saffa 94
Kareem 94
Ahlam 83
Nora 83
Aisha 72
Hamida 94
Hwidaa 86
-
7/30/2019 Production Balancing
41/44
Skills inventory. Fronts section
Operator/job titleSergefront
Attach
Flly &zipper Run pkt Topsew Secure J Runstitch topsew crotch bartack
Asmaa 101
Nadra 117
Mahmoud 75
Eman 76
Rasha 78
Karema 100
Alham(2) 85
Afaf 120
Hamida(2)
78
Amina 100
Fatma 48
-
7/30/2019 Production Balancing
42/44
Skills inventory. Fronts section
Operator/job title
Serge
front
Attach
Flly &
zipper Run pkt Topsew Secure J Runstitch topsew crotch bartack
Samah 120
Ahmad 100
Hamdia 102
Bossi 80
Abbier
90
-
7/30/2019 Production Balancing
43/44
Initial balance
No skills matrix was available. Compiled
by engineers doing cycle timing.
No means available of measuring
efficiency.
Floaters included in section.
No section absence information available.
Target of 400 hour imposed by
management.
-
7/30/2019 Production Balancing
44/44
Initial calculation 400 hour
SMV = 3.278 per front
27 operators available
400 per hour needed. 400 x 3.278 = 21.86 std hours needed.
60
21.86 = 81% efficiency needed (absence)27