Line Balancing - What is it ?

Here is a simple definition and example of line balancing : 6 sigma training

Everyone is doing the same amount of work

Doing the same amount of work to customer requirement

Variation is smoothed

No one overburdened

No one waiting

Everyone working together in a BALANCED fashion

Here we see operator number 1 over-producing, thus creating the other 6 wastes.

We simply re-balance the work content (Re distribute some of the work), using a line balancing board or Yamazumi board as it is often known

In the example shown above, the line balancing exercise looks incredibly simple - So why doesn't everyone do it ?

There are two vital pre requisites to line balancing which must be in place before a line balancing exercise can take place.

These are:

Takt Time & Standard Work

Takt Time

Takt Time is the production "Drumbeat" based on customer demand

Standard Work

Whether you use Standard work combination tables, Standard work instruction sheets or any other Standard work documentation will depend upon the type of work involved

Standard Work instruction sheets provide a detailed description of HOW to do a particular step of a work operation

Benefits of the pre requisites to line balancing:

Takt time maximises the productivity due to:

Easily managed processes

Output of each process matches customer demand

Standard Operations provide:

Capable and repeatable processes

Process control at source

Improves accuracy of planning

Better adherence to plans

A platform from which continuous improvement can be made

Reduced costs

Improved quality

Basis for training

Line Balancing