In most cases, the culprits for poorly functioning production can be found in one of the following categories:

• Processes

  Check whether all processes are running smoothly and optimize existing processes if necessary. Think about how you can avoid bottlenecks and speed up processes.

• Material stocks (stocks in material zones)

  Check your material stocks regularly and optimize them to avoid bottlenecks. Ensure that sufficient material is available in the material zones to guarantee smooth production.

• Qualification of employees

  A qualified workforce is an important factor for optimal balancing. Invest in the further education and training of your employees.

• Work materials

  Make sure that all the necessary tools and machines are available. This will help you avoid bottlenecks and keep production running smoothly.

The effects extend to the entire production process. That doesn’t have to be the case! We will show you how to get your line(s) in peak condition. You can update your assembly line with the following steps.

What exact steps should you take to optimize the balancing of your assembly line?

• 1. Create a process map

  Before you begin the balancing process, it is important to have a deep understanding of your manufacturing processes. You should know which machines and equipment are used, how the work tasks are divided up and how the materials and parts flow through the process.

• 2. Identify time wasters

  Identify the processes that take up the most time. Once you understand the processes, you can identify weak points that affect line balancing. These could be bottlenecks in material movement, slow machines or unbalanced work tasks. Only by identifying weak points can you make targeted improvements.

• 3. Implement cycle times

  Set cycle times for the individual processes. Calculate the cycle time for your line and determine the required capacity at the work stations on this basis.

• 4. Assignin work tasks

  Assign tasks to the individual workstations and ensure that the resources are utilized and the cycle is adhered to. To make optimum use of resources, reduce employee routes.

• 5. Optimize the processes

  Simplify processes and increase the degree of automation.

• 6. Check and adjust

  Analyze your processes regularly and adjust cycle times and workflows.

Various methods are available to support you in the balancing process. You can fall back on tried and tested approaches here.

• CIP (Continuous Improvement Process)

  Conduct regular Kaizen events and other continuous improvement initiatives to optimize processes and cycle times.

• Lean Manufacturing

  Use methods such as the 5S method (sort, systematize, keep clean, standardize, self-discipline), SMED (Single Minute Exchange of Die) and Value Stream Mapping to simplify processes on the line and save time.

• Employee participation

  With quality circles or empowerment, you involve employees in the implementation of improvements. This optimizes work processes and also increases motivation and satisfaction.

• Monitoring with KPIs (Key Performance Indicators)

  KPIs are measurable key figures that you can use to monitor the performance of processes in your production. Examples include the production rate, the failure rate and the throughput time.

The more complex the production, the more variants a product range comprises, the more complex the planning and balancing with the above-mentioned methods and Excel. Especially with high quantities and variant-rich production, it is easy to lose the overview and encounter restrictions. Whether in the automotive industry, construction machinery or the manufacturing industry – the purchase of a tool can help to get processes under control again.

• Analysis and planning tools

  There are many analysis tools that can be helpful in balancing manufacturing processes. These include, for example, simulation software that allows you to test changes to processes without actually having to make any physical changes.

• Takt time tools: Andon, Takt Time Clock, Pareto Diagrams

  Another way to optimize the balancing of production processes is to use special balancing software. These tools offer a variety of functions. Use tools such as Andon systems, the cycle time clock and Pareto charts to monitor and optimize cycle times on the line.

• Simulation software

  These tools are used to create a digital twin of the factory. In digital reality, you can simulate, analyze and optimize processes. >> Read here about the advantages of simulation software

• Manufacturing Execution Systems (MES) – Tools

  These tools can be used to automate and control production processes. However, before an MES is implemented, assembly and logistics should be properly planned. This is the only way to identify all requirements and begin the search for the right system.

• Improved efficiency

  Throughput times are shorter as there are fewer delays and bottlenecks. This increases production efficiency and gives you more free capacity.

• Higher quality

  Well-optimized production increases the quality of the goods produced by ensuring that all machines and systems function properly.

• Cost savings

  By avoiding bottlenecks and shortening throughput times, you also save costs in production.

Are you still optimizing your assembly line with Excel? But are you reaching your limits? We’ll show you how to get your assembly processes under control with our ipolog software!