Benefits of Line Balance
In manufacturing, efficiency is a critical factor that can make a huge difference in a company’s success. One important concept in achieving efficiency within production processes is line balance. Properly distributing the workloads between the operators in the production line to optimize productivity and minimize bottlenecks is the main aspect of line balance. If any company implements this concept properly, it can significantly impact production output, lead time, and overall operational costs.
To deeply understand the line balance of a production line, let’s assume a line where products move through different stages of a stitching line. Each stage operation is operated by operators or automated machinery. This stitching line becomes an ideal line when the time required to complete tasks at each stage is close to each other, ensuring that no single operation becomes a bottleneck that slows down the entire process.
The main aim of line balance is to achieve the equilibrium of work tasks across the production line by analyzing and optimizing, which leads to synchronizing the speed of each workstation to increase productivity of the line, thereby maximizing efficiency and minimizing idle time.
Importance of Line Balance:
01. Reduce Cycle Times: As you can see in the above picture, before line balance, Operator C needs more time to complete their task, while Operator D completes their task quickly compared to Operator C. After line balance, the cycle time of Operator C is reduced, balancing the line cycle time of each operator. One of the main aspects of line balance is to reduce the cycle time of the operators in the production line to readjust the line and achieve the production target.
02. Properly Optimized Workload: The production line operators work smoothly when workloads are evenly distributed throughout the line, and products move through each stage at a consistent pace. This properly optimized workload helps meet demand efficiently without overburdening any particular operation.
03. Resource Utilization: Line balance ensures that resources, including manpower and machinery, are utilized effectively.
04. Cost Efficiency: Properly balanced lines translate to lower operational costs. Reduced cycle times, optimized throughput, and effective resource utilization result in lower operator costs, reduced inventory holding costs, and increased productivity of the line, which leads to overall profitability.