line balance optimisation
TRANSCRIPT
Line Balance Optimisation (LBO) Overview
www.optimumfx.com
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