Line Balance Optimisation is about maximising output at the critical machine by reducing or eliminating impact of upstream or downstream machine stoppages.
2. 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
3. The Basic Rules
There 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
4. 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
Filler
30,000 uph
Packer
36,000 uph
Labeller
33,000 uph
Depalletiser
33,000 uph
Palletiser
40,000 uph
Normally Full
conveyors
Normally Empty
conveyors
Example Production Line:
(generic bottling ine shown)
Uph = Units per Hour
5. Vision of Perfect Flow
To 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
6. 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.
7. Perfect Flow, the Multiple Hour-glass Model
Normal Running Machine Stopped
Stop
Machine Restarted
Restart