UNDP Training

Work in Progress & Line Balancing

1TopicsWork in ProgressBalancingReasons of BalancingBalancing: How to Start?Balancing ToolsBalancing Matrix

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Work in Progress/ProcessWork in process (acronym: WIP) or in-process inventory includes the set at large of unfinished items for products in a production process. These items are not yet completed but either just being fabricated or waiting in a queue for further processing or in a buffer storage. In manufacturing WIP stands for something that has been worked on such that it is no longer viable as raw materials while not yet sellable as a finished product

Garment/Parts issued to sewing from cutting and still in sewing lines are WIP of sewing linesComplete parts are only considered as WIP

1.3WIPDay1

Day 21.Starting WIP200 piecesCutting issued to Sewing5000 PiecesOutput1000 piecesWIP200+5000-1000 = 4200 piecesCutting Issued to sewing 5500 piecesQuality Rejection100 piecesOutput2000 piecesWIP4200+5500-2000 =7700 pieces4WIP1.FrontBackInitial WIP00Loading50005000Output20001500WIP5000-2000=30005000-1500=35005WIP1.Front WIPBack WIPAssembly WIPTotal WIP6WIPPocket Hemming=800 PiecesBack yoke attach=500 piecesBack seat attach=300 piecesBack pocket attach=200 piecesTotal WIP in back section=??1.7WIPWIP is made up of all garments and their parts that are not completely finished. For example a bundle of shirts that has everything attached but has no bottom hem.We can measure WIP in Units/Pieces or in units of time. For example, if we know that an operation A takes 0.5 minutes per unit to process and we have 5 bundles of 12 units each then we have 30 minutes of WIP for that operation (5 X 12 X 0.5).In some factories, some operations have days of inventory waiting to be processed! This is unacceptable for many reasons.1.8

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High Inventory/WIPLow WIP forces us to address issuesHigh Inventory/WIPInventory Hides Problem10BalancingWhat is a balanced production system?System where you meet the production expectations (output) and find the same amount of work in process at every operation at any point in the day. To be able to achieve this is extremely difficult. If we choose to have balanced inventories at the end of every day that will prove to be a reasonably difficult challenge.

How do you keep all operations producing at the same rate? This is very difficult since operators skills vary. We are able to balance using multiple operators or Utility operators that fill holes in production.2.11Reasons for BalancingHelp supervisors undertake regular changes because of :Machine break downOperator beats target (shortage and excess)AbsenteeismOperator hurt/sickCutting not correctAlterations

Benefits of Line BalancingBalanced line helps in consistent productionKeep inventory costs lowKeeping normal inventory levels lets the operator work all day long giving him/her the opportunity to increase his/her efficiencyKeeping the line balanced lets the supervisors improve other areas like quality, methods improvement etc. because they can use their time betterIt is very important that all supervisors put line balancing in their daily plans every day.

3.12Balancing- How to startDetermine how many operators are needed for each operation for a determined level of productionNext determine how much WIP we need to anticipate production problems. We recommend a 1-hour inventory level for each operation. A good range would be from 30 min to 120 min inventory level. Any variation outside this range should be avoided. A variation of this magnitude signifies an unbalanced line and should be looked into immediately.Rules for balancingHave at least hour and maximum 2 hours of WIP for each operationSolve problems before they become largerOperator should be used in the primary operation/ operation with maximum capacityShifting should be minimum for 2 hoursLine supervisors who are directly involved in each line are most suited to balance their own individual section/line.4.13Balancing ToolsThere are a number of tools that can be used for balancing. These are applied according to the plants needs.The most basic ones are Production Sheets / Gum SheetInventory levels by operation and bi-hourly production monitoringProduction BoardsDaily sewing report5.14

Bi-Hourly Report155.OUT PUT

LOWHIGHLOWWIPLine Balancing What to do when?166.17Thank Youbi-hrS.No.OperationOpeningOperatorProductionProductionProductionProductionProductionTotalClosingWIP11:0013:0015:3017:30OvertimeProductionWIPOTLine In ChargePM

&L&"Arial,Bold"DATELINE&C&"Arial,Bold"&14Bi-Hourly Production Report&LBRFL-Osmanabad&R&"Tahoma,Regular"&8t e c h n o p a k