Definition of the hottest production line balance

2022-08-12
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Definition of production line balance

I. definition of "beat", "bottleneck", "idle time" and "process balance"

the "cycle time" of a process refers to the interval between the continuous completion of the same two products (or two services, or two batches of products). In other words, it refers to the average time required to complete a product. Beat is usually used to define the unit output time of a specific operation or link in a process. If the products must be produced in batches, the beat refers to the interval between two batches of products. In process design, if the necessary output of a process every day (or other unit time period) is given in advance, the first thing to consider is the beat of the process

the slowest step in a process is usually called "bottleneck" 。 The bottleneck in the process not only limits the output speed of a process, but also affects the production capacity of other links. More broadly speaking, the so-called bottleneck refers to the various factors that restrict output in the whole process. For example, in some cases, the possible shortage of manpower, the failure of raw materials in time, the failure of equipment in a certain link, and the blockage of information flow may all become bottlenecks. As the literal meaning of "bottleneck", the size of the mouth of a bottle determines the speed of liquid flowing out of it, and the bottleneck in the hardness production operation process restricts the output speed of the whole process. Bottlenecks may also "drift", depending on the products produced or the manpower and equipment used in a specific period of time. Therefore, enough attention should be paid to process design and daily production operation in the future

another concept associated with tempo and bottleneck is "idle time" in the process. Idle time refers to the time during which effective work tasks are not performed during working hours, which can refer to the time of equipment or people. When the tempo of each process in a process is inconsistent, other processes other than the bottleneck process will generate idle time

this requires balancing the production process. Most of the production lines in the manufacturing industry are multi process flow continuous production lines after subdivision. At this time, due to the division of labor, the difficulty of operation is simplified, and the proficiency of operation is easy to improve, thus improving the efficiency of operation. However, after such fine division of operations, the operation time of each process can not be exactly the same in theory and reality, so there must be a bottleneck phenomenon of inconsistent beats between processes. In addition to the unnecessary loss of working hours, it also causes a large number of process accumulation, that is, the occurrence of delayed products, and even the suspension of production. In order to solve the above problems, it is necessary to average the operation time of each process and standardize the operation at the same time, so that the production line can move smoothly

"process balance of production line" means averaging all processes of production and adjusting each operation load to make each operation time as close as possible. It is the most important problem that the formulation design and Utilization Research of mixed products must be considered in the production process design and operation standardization. The purpose of process balance of production line is to make it easier to understand the necessity of "one flow" and the compilation method of "cell production" by balancing the use site of production line. It is the basis of all new theories and methods

second, the significance of balancing the production line

the following purposes can be achieved by balancing the production line:

1. Improve the work efficiency of operators and equipment tooling

2. Reduce the man hour consumption of a single product and reduce the cost (equivalent to increasing the per capita output)

3. Reduce the WIP of the process and truly realize "one flow"

4. Realize unit production on the basis of balanced production line, improve production adaptability, respond to market changes, and realize flexible production system

5. Through the balanced production line, it can be comprehensively applied to all ie techniques such as program analysis, action analysis, layout analysis, handling analysis, time analysis, etc., so as to improve the overall quality of all staff

III. Calculation of process balance rate

to measure the overall balance of the process, we must set a quantitative value, that is, the balance rate of the production line or the balance loss rate, expressed in percentage

first of all, it should be clear that although the process time of each process is different, as mentioned above, there is only one process time that determines the operation cycle of the production line, that is, the longest process time, pitch time, which is equal to cycle time. Another calculation method can also get that we must keep the resource saving as the unwinding point to cycle time, that is, from the average output per hour, we can get the CT (Q, output per hour) of a product

cycle time (CT) =pitch time=3600/q

1. Balance calculation formula of production line

balance rate = (total time of each process/(number of jobs *ct)) *100= (∑ ti/(number of jobs *ct)) *100

2. Balance loss rate calculation formula of production line

balance loss rate = 1-balance rate

4 The basic principle of improving the balance rate of the production line is to adjust the operation content of the process to make the operation time of each process close to or reduce this deviation. The following methods can be followed during implementation:

1. First of all, we should consider the operation improvement of the bottleneck process. The method of operation improvement can refer to the improvement method of program analysis, action analysis, tooling automation and other ie methods and means

2. Share the operation contents of the bottleneck process to other processes; The presidential career should be the beginning of bending over and listening

3. Increase the number of operators. As long as the balance rate is increased, the per capita output is increased, and the unit product cost is also reduced

4. It is relatively easy to balance when there are many operations by combining relevant processes and re arranging production processes

6. Decompose the process with short operation time and arrange the process to other processes. (end)

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