The key to a well-balanced manufacturing line is to know how it should be set up. Follow our lead as we walk you through resolving this issue.
Learn what must be done.
The first step in obtaining line balance is to identify each process step in your production procedure. It’s obvious that you should start by listing all of these steps, but don’t forget to account for any transitional steps that need to be taken along the way. Between the four primary steps (frame assembly, body assembly, drivetrain installation, and paint) and the final step of painting a vehicle, a car factory, for example, may engage in a number of ancillary operations. You can also include jobs that happen less regularly or are done by the same individual only once every two months or so (like repairing worn-out parts). Geekzilla Autos: Embracing the Next Generation of Geek Culture and Innovation in Automotive
Each step of your manufacturing line(s) should be described in depth and listed in the order in which it occurs. By analyzing the chronological order of events, we can identify barriers in the production and fix them. Tanzohub The New Standard for Teamwork and Project Management
Determine how much time is needed for each step.
You can’t draw a straight line without first determining the appropriate length of each segment. Doing so will help you identify any delays or bottlenecks in the system. There are three possible states for a manufacturing machine when producing a single unit of output: waiting for materials or parts, waiting for its operator’s next move, or preparing another unit for assembly. Read more
To establish a time frame, one must:
Estimate the duration of any potential delays in production and evaluate whether they are truly essential. Downtime and risk are both increased when two workers handle potentially dangerous equipment at the same time without proper supervision, as happens, for example, when one worker changes parts while waiting in queue behind a machine that has already been set up by another worker but hasn’t started yet.
Find the peak output by estimating how long it would take one person to finish everything. For this example, let’s say that the setup and cleanup time for a 100-unit batch takes four hours. If we divide 100 by 4, we can make 25 batches every day. Fast when measured against the average work week of 40 hours. We may use these numbers to estimate that we need around an hour between each batch to allow for unforeseen problems like running out of tools, etc. Any and any means. Achieving Great Results with China SEO Xiaoyan’s Digital Marketing Strategies
A manufacturing facility needs several different sorts of resources in order to function properly. Tangible resources include things like manufacturing machinery, but intangible resources like human capital are more difficult to quantify. There are two types of input in a manufacturing process:
“Line capacity” describes the maximum number of items that may be manufactured in one hour by all of the machines on a given manufacturing line.
Tools, such as gauges and assembly jigs, used to monitor the precision and accuracy of manufactured goods. Read also
Determine how many hours of labor will be needed.
Understanding how many man-hours will be needed to get a production line up and running well is essential.
Workers’ weekly man-hours can be determined by multiplying their total number by their average hourly output. The result is the average weekly work schedule for each employee:
There are a total of 12 units every day (two operators times six units per hour).
12 units divided by 5 days = 2.4 units every day.
Seven days of work at an average output of 2.4 results in a weekly output of 17 man-hours business.
Determine how many people should be on staff.
The critical route must be understood, and a firm grasp on how many operators is required, before an optimal number can be determined. Finding the optimal time for each operator to complete their task and hand off their job to the next operator in your process can be challenging.
How many operators you need depends on the time and resource constraints you face. If one part of your production line is moving more slowly than the others, it could be because of a lack of workers, but if everything is moving more slowly than usual, it’s probably because there are too many people working at once and not enough material is moving through each stage, as happens when demand spikes.
Having a larger-than-usual workforce may be needed all year round because there will always be downtime while things move through the various stages of production business, thus this isn’t just an issue during times of high demand.
Try to guess how long it will take to get the goods.
When calculating how long you waited for the product, be careful not to add the same amount of time twice. If an operator has to wait for parts from another department before they can begin working on their sector of the queue, that time should be included in as well.
The average wait time per operator can be calculated by taking the total wait time and dividing it by the number of operators. This allows for easier line-by-line comparisons and the pinpointing of prospective manufacturing efficiency benefits.
A solid understanding of the statistics involved is necessary for knowing how to balance your production line. Finding out how many people hours will be needed is the first stage in creating a formula for balancing a queue. The number of hours in a shift can be calculated by dividing the daily man hours total by 24.
When you know how many people can work on your line at once, you can figure out how many products they can produce every hour without getting burned out business. To get this number, divide the unit price by 90 (the typical hourly production rate in the industry).
Based on the following assumptions: 10 workers on shift, 48 total working hours, and a 4-minute work cycle for each worker:
With 10 workers producing 2 units every minute, that’s 2080 units per day. By dividing 2080 by (48 * 60) minutes, we get an average of.463 units or parts per minute business. This means that each worker needs to produce about eight parts each minute. Read more
Conclusion
You can make the best decision for your plant now that you have all the information you need. Adding a second shift of workers is one solution to the issue of having too many operators at once. If there aren’t enough operators, the wait times are likely causing bottlenecks, in which case it would be beneficial to hire more personnel.
