ME Initiatives 2021

LBR above 70% & 5% improvement

Feb 2021
 LINE BALANCE
RATE

• 2021 Manufacturing Excellence One Pager

• Progress in 2020

• Initiative 2021 Target

• Training Deck
 2021 MANUFACTURING EXCELLENCE ONE PAGER
Management upskilling, ME basic enhancement , digital manufacturing acceleration

People Process Production Methods Work Environment

Production Methodology Development

Worker Skill preparation: • 80% coverage by - aSC, automatic • Development H/O package incl
• Multi skill operators 100% fulfill b4 hanger line, flat material handling method and motion for new product
season start, digital skill matrix without bundle type & top volume
• ( phase I- within same T1 group)
Defect correction training Workstation Standardization
• Workstation standardization:
Management upskilling: ( 2021~2022)
Digital Manufacturing

Basic Management Adoption Upstream process: Cutting,

• Standard work in all Tiers (Line leader,
• Seamless change over (no of C/O • Template & Automation 25% SMV Embellishment, Supermarket. PPA, aSC
supervisor, floor manager)
& Hanger line
• Management upskilling - real time data reduction, COPT reduction 30% or less coverage
exploration decision making, 2021 phase 1 than 3 *SMV unit ) • Auto folding & Bagging 30% vol
received training, measured by project ; 2022 phase • LBR above 70% & 5% improvement coverage
2 measured by production station.
Automation Utilization Advance Capability *
• OEE - automatic machine OEE • Auto fabric inspection in T2
measurement/ improvement of • Auto Picking and positioning
Manpower vs machine balancing • Curve seam /3D stitching

DIGITAL MANUFACTURING
1. E2E real time data connection and display:
T2 shipment & quality , T1 raw material W/H, cutting, supermarket, production status, DT, quality inline & end line.
2. Production Performance tracking & display, real time data exploration decision making
3. Production simulation pilot** - Digital manpower machine &line layout set up

*Advance capability – collaboration with pilot factories only

Carry Over from 2020 New task in 2021 **Production Simulation Pilot- strategic suppliers only
2020 LINE BALANCING RATE
GLOBAL AVERAGE LBR ACHIEVED 73.3%, 7.8% ABOVE MINIMUM LBR (65%)

4
2020 LINE BALANCING RATE
GLOBAL AVERAGE LBR ACHIEVED 73.3%, 7.8% ABOVE MINIMUM LBR (65%)

5
BASIC MANAGEMENT- LINE BALANCE RATE
2021 Target: LBR Above 70% & 5% Improvement

1 2

LBR ABOVE 70% 5% IMPROVEMENT

1. LBR ABOVE 70%

➢ Explanation of the challenges we faced

in 2020

➢ What is the Best practice we want you

to adopt

➢ Opportunities & Tactics to improve Line

Balancing
LBR ABOVE 70%
 WHAT ARE THE CHALLENGES WE FACED IN LINE BALANCE?

People Environment Method

➢ High Absenteeism ➢ No action for bottle neck operations

➢ Mechanic skill level ➢ Covid-19 ➢ More motions
➢ Lack of Multi-skill / jumpers than GSD
➢ IE / Line Supervisor skill level
Method not following GSD Lack of IE skills in
Lack of skilled worker 2020 Global LBR:
line balancing
Machine / Template Right material not 73.3%
not ready available for training
➢ No calibrated quality ➢ Shortage of works aids ➢ Lack of Material
criteria Requirement ➢ Material / Trims
➢ Lack of machinery quality issue
buffer for QCO
➢ Layout Limitations

Measurement Machinery / Materials

Equipment

* Numbers- the causes we found in year 2020

8
CASE I - DIGITALIZE IE LINE BALANCING TASK

Background: Digitalize IE Line Balancing task

Objectives: Digital IE tool

(Skill math)
Operators Skills Inventory System
• Operator skill database
• Provide factual information for training
needs analysis
• Capture on time operators learning
curve

Dynamic Line balancing system

• Easy to use and reduce cycle time
study.
Operator performance information Line balancing real time digital board
• Provide accurate line balancing
simulation and prevent trial and error.
• Improve line balancing Rate.

9
CASE I - DIGITALIZE IE LINE BALANCING TASK

Line balancing simulation

Key Elements

• Centralized operators training

matrix by product

• Provide accurate Line

Balancing simulation and
prevent trial and error.

• Improve Line Balancing Rate.

Video
10
OPPORTUNITIES & TACTICS TO IMPROVE LBR

1. How the Line Balancing Rate impact the Efficiency?

• High LBR (70%) will impact positively the efficiency through reducing waiting time and
focusing in keeping the bottleneck operation under control / balanced

2. What happen when the PRE-LBR% is below the Global target of 70%?
• Ensure Line Balancing simulation / PRE-LBR% is done
• In case, your PRE-LBR% is lower than 70%, you need to continue finding solutions until
achieve the target (no implementation until PRE-LBR% = > 70%)

3. How to monitor the LBR effectively in the production line?

• Clearly define R&R of the IE and Line Leader in the Line balancing (following standard work)
• Ensure the PRE-LBR% is fully met and utilize cycle time and takt time visual in the machine
• Focus on skill enhancement of IE / Line Leader with on site
training/coaching on LB

11
OPPORTUNITIES & TACTICS TO IMPROVE LBR

4. What are the action to support the Bottleneck operation?

• Ensure bottleneck is a single operation not a group of operations
• Ensure you are applying the best method
• Activities to reduce Bottleneck Cycle Time
• Consider using Templates / Automation
• Review the operations' assignment according to skill matrix (right operator in the right
operation)

5. What is the action plan when you have high absenteeism in the critical operation or the
multiskilled operator are not ready?
• Increase to a bigger amount of helpers / jumpers
• Skill set preparation before season starts
• Develop strong program to buildup multi-skill operators

12
BASIC MANAGEMENT- LINE BALANCE RATE
KEY TAKEAWAY

1- LBR Target for 2021 above 70% and 5%

Improvement

2- Digitalization of skill matrix, Line Balancing

Simulation

3- Opportunities and Tactics to Improve Line

Balance Rate
THANK YOU
ME Initiatives
Line Balancing Training
Initiative: Line Balance Rate above 70% & 5% improvement

Background: Why we want to do that?

Line Balance: Benefits of Line Balance: Prior to style changeover, a line

balance plan is used to determine:
Way of adjusting each operator’s 1. Everyone is doing the same amount
loading to make each operation’s time of work • Machine Requirement:
value almost the same. • Number of units
2. Doing the same amount of work to • Machine type
customer requirement
• Operator:
3. No one overburdened • Number of operators
• Required skill level
4. Variation is ‘smoothed’
• Sequence of Operations in the
5. No one waiting production line

6. Everyone working together in a

BALANCED fashion

16
Initiative: Line Balance Rate above 70% & 5% improvement

How to Achieve?

Why balancing is important in setting • How to determine bottleneck How to Analyze the Line Balance?
up the line? operation?
To eliminate excessive work in progress • Through WIP (Work Using Time Observation Sheet:
(WIP) or bottlenecks In Progress) • Production output
• Cycle Time Check • SMV
What is Bottleneck? • Cycle Time
• Operators completing sewing How to Achieve the Line Balance?
operations of higher SMV’s,
compared to all other operators • Identify the constraint
(bottleneck)
• Holds up the work for operators • Squeeze the constraint
further down the line causing • Support the constraint
production stoppages • Elevate the constraint
• Do not let the inertia become the
constraint

17
Initiative: Line Balance Rate above 70% & 5% improvement

How to Measure and Track the Progress?

Line Balancing Process:

CYCLE TIME
How to calculate the Line Balance Rate?
• Share Method
• Rearrange bottleneck operation
• Improve the bottleneck
LBR= Total Cycle Time X Bottleneck’s* X 100% operation to reduce it’s time
number of total cycle time value
OPERATOR 1 2 3 4 5
operators • Improve handling & fabricate
machine folders & attachments
• Reduce cycle time by
Target Line Balance Rate > 70%
additional/shared operator

CYCLE TIME
• Separate & Eliminate operation
*Bottleneck cycle time means highest cycle time elements
of the operator

OPERATOR 1 2 3 4 5

18
 Summary Activity: Line Balance
Build Sewer Database
/ • IE updates highest potential efficiency of the sewer on the Sewer Database
1 Pre-set Before QCO • IE use the Sewer Database for initial line balancing and sewing line layout
• Design the line balance chart using historical data
Line Balance

• IE continuously monitor actual efficiency of the sewer and update the data
• Review quality level, if it is consistent after 2 hours of continuous production then do the
2
First actual During QCO new Balance
Line Balance • Create actual line balance chart

• IE conduct cycle study, update LB Graph compared with target LB rate

Line balancing • IE identify the constraint operation to make sure they have correct method, right quality,
3 study in 2nd days after After QCO speed and appropriate number of operators.
changeover • Update the line balance chart

Review the line • IE continuously monitor actual performance of the sewer and update the data
4
After QCO • Optimize the right number of operators to improve the LB rate (example: from 3 to 2.5
balance 5th day after operators)
changeover
T1: LB should be updated at the end of each line
19
Initiative: Line Balance Rate above 70% & 5% improvement

How to Measure and Track the Progress?

Line Balancing Process:

CYCLE TIME
How to calculate the Line Balance Rate?
• Share Method
• Rearrange bottleneck operation
• Improve the bottleneck
LBR= Total Cycle Time X Bottleneck* X 100% operation to reduce it’s time
number of total cycle time value
OPERATOR 1 2 3 4 5
operators • Improve handling & fabricate
machine folders & attachments
• Reduce cycle time by
Target Line Balance Rate > 65%
additional/shared operator

CYCLE TIME
• Separate & Eliminate operation
*Bottleneck cycle time means highest cycle time elements
of the operator

OPERATOR 1 2 3 4 5

20
Line Balance Tracking List

COPT (*SMV) Day I Efficiency Day 4 Efficiency Reason for

Changeover Changeover
Line Name Pre LBR Latest LBR missing
Date Category
Actual COPT Target COPT Actual Target Actual Target target
Line
balance% is
LINE 11 17-Jan A 8 6 35% 40% 75% 70%
lower than
80%
Line
balance% is
LINE 11 25-Jan B 8 5 40% 50% 75% 70%
lower than
80%

21
 IE:_______________________
SCENARIO#1- 1 OPERATOR SUPPORTS BOTTLENECK OPERATION Line Leader:________________
(OPERATION#3) Date:______________________
LINE BALANCING GRAPH IN EACH LINE LBR Calculation: _____________
BEFORE LINE BALANCING

• LBR =(24+23+35+26+28)/5*35*100% = 78%

40 120%

35
100%
Seconds

30 30
80%
25

20 60%
35
15
28 40%
26
24 23
10
20%
5

0 0%
Operator 1 Operator 2 Operator 3 Operator 4 Operator 5
Cycle time Takt Time Efficiency

22
SCENARIO#1- LINE BALANCING GRAPH IN EACH LINE IE:_______________________
DURING LINE BALANCING- ONE OPERATOR MANAGE TWO OPERATIONS Line Leader:________________
Date:______________________
• Identify Operator#3 is bottleneck LBR Calculation: _____________
• Kaizen for operator#3 method or improve operator#3 skill
• Consider neighbor operator(Operator#2) to support bottleneck operation if operator#3 can not meet takt time after
initial kaizen
• In our case, we will shift operator#3 ’s work to operator#2, then how to calculate operator 2's cycle time?
40 120%

35
100%
Seconds

30 30
80%
25 ?

20 60%
35
15
28 40%
26
24 23
10
20%
5

0 0%
Operator 1 Operator 2 Operator 3 Operator 4 Operator 5
Cycle time Takt Time Efficiency

23
SCENARIO #1- HOW TO CALCULATE OPERATOR 2 CYCLE TIME IN LINE BALANCE CHART?

Given:
1. Takt time is 30 seconds
2. Operator#3 Cycle time is 35sec, which is the bottleneck, operator#2 is 23 sec, they physically close each other
3. We ask operator#2 partially to support operator #3, but even that, operator#2 is less than takt time
4. When operator #2 performs operator #3 ‘s operation, the cycle time will be: 40 secs
Question: how to calculate operator#2 cycle time in line balance chart?
Solution:
1. Takt time is 30 sec, then hourly target output will be: 60mins*60secs/30secs=120pcs
2. Operator #3 hourly output: 60mins*60secs/35secs=102 pcs
3. The hourly gap: 120 -102= 18 pcs, which we will rely on operator#2
4. Then operator #2 cycle time will be weighted average cycle time:( Operator#2 cycle time for operation#2 *hourly
target output+ operator#2’s cycle time for operation#3* additional output of operation#3 by operator#2 ) /
target output in takt time
= (23secs *120pcs+40secs*18 pcs)/120pcs= 29secs

24
SCENARIO #1- HOW TO CALCULATE OPERATOR 2 CYCLE TIME IN LINE BALANCE CHART?

Total seconds in an hour Takt time Hourly target output in takt time

3600SECS 30 120PCS

Operator#3 cycle time for operation #3 Total seconds in an hour Operator#3’s output for operation#3

35SECS 3600SECS 102PCS

How many pcs operator#2 needs to support

Operator#2 cycle time for operation #2 Operator#2’s cycle time for operation#3 operation#3?
Total seconds in an hour

23SECS 40SECS 18PCS

Additional output of
Operator#2 cycle time Hourly target output in Operator#2’s cycle
operation#3 by
for operation #2 takt time time for operation#3
operator#2
23SECS 120PCS 40SECS 18PCS
Operator#2
New cycle time 29SECS
Hourly target output in
takt time
120PCS
25
 IE:_______________________
SCENARIO #1- LINE BALANCING GRAPH AFTER LINE BALANCING Line Leader:________________
Date:______________________
LBR Calculation: _____________

• LBR =(24+29+30+26+28)/5*30*100% = 91%

35 120%

30 30 100%
Seconds

6
25
80%

20
60%
15 30
28
26
24 23 40%
10

20%
5

0 0%
Operator 1 Operator 2 Operator 3 Operator 4 Operator 5
Cycle time Takt Time Efficiency

26
 IE:_______________________
SCENARIO#2 - 2 OPERATORS PERFORM ONE OPERATION Line Leader:________________
(OPERATION #3 ) Date:______________________
LINE BALANCING GRAPH IN EACH LINE LBR Calculation: _____________
BEFORE LINE BALANCING

• LBR =(24+23+55+26+28)/5*55*100% = 57%

60 120%

50 100%
Seconds

40 80%

30 30 60%
55

20 40%

26 28
24 23
10 20%

0 0%
Operator 1 Operator 2 Operator 3 Operator 4 Operator 5
Cycle time Takt Time Efficiency

27
 IE:_______________________
SCENARIO#2 - 2 OPERATORS PERFORM ONE OPERATION Line Leader:________________
(OPERATION #3 ) Date:______________________
LBR Calculation: _____________
• Operation#3 is bottleneck operation, far higher than the
takt time(30secs), we will assign 2 operators for
operation#3

35 120%

30 30 100%
Seconds

25
80%

20
60%
15
28
? ? 26
24 23 40%
10

20%
5

0 0%
Operator 1 Operator 2 Operator 3-1 Operator 3-2 Operator 4 Operator 5
Cycle time Takt Time Efficiency

28
SCENARIO#2 - HOW TO CALCULATE OPERATOR 3-1&2 CYCLE TIME IN LINE BALANCE CHART?

Given:
1. Takt time is 30 seconds
2. Operation #3 Cycle time is 55secs, which is the bottleneck
3. We assigned 2 operators (Operator3-1, Operator 3-2) to perform Operation #3
4. Actual cycle time:
• When Operator 3-1 performs Operation #3, the cycle time is 63secs
• When Operator 3-2 performs Operation #3, the cycle time is 55 secs
Question: how to calculate operator 3-1&3-2 cycle time in line balance chart? and what is new LBR%?
Solution:
1. Takt time is 30 sec, then hourly output will be: 60mins*60secs/30secs=120pcs
2. Operator #3-2 cycle time is competitive, so we will fully deploy Operator #3-2 in operation #3
3. Hourly output for Operator #3-2 : 60mins*60secs/55secs=65 pcs
4. The hourly gap: 120 -65= 55 pcs, which we will rely on Operator 3-1
5. Operator #3-2 cycle time in line balance chart will be: 55secs*65pcs/120pcs=30 secs
6. Operator #3-1 cycle time in line balance chart will be: 63secs*55pcs/120pcs= 28.8 secs

29
 IE:_______________________
SCENARIO#2 - LINE BALANCING GRAPH BEFORE LINE BALANCING Line Leader:________________
BEFORE LINE BALANCING Date:______________________
LBR Calculation: _____________

• LBR =(24+23+55+26+28)/5*55*100% = 57%

60 120%

50 100%
Seconds

40 80%

30 30 60%
55

20 40%

26 28
24 23
10 20%

0 0%
Operator 1 Operator 2 Operator 3 Operator 4 Operator 5
Cycle time Takt Time Efficiency

30
 IE:_______________________
SCENARIO#2 - LINE BALANCING GRAPH AFTER LINE BALANCING Line Leader:________________
Date:______________________
LBR Calculation: _____________

• LBR =(24+23+28.8+30+26+28)/6*30*100% = 89%

35 120%

30 30 100%
Seconds

25
80%

20
60%
15 28.8 30
28
26
24 23 40%
10

20%
5

0 0%
Operator 1 Operator 2 Operator 3-1 Operator 3-2 Operator 4 Operator 5
Cycle time Takt Time Efficiency

31
 IE:_______________________
SCENARIO#3 - 2 OPERATORS PERFORM ONE OPERATION Line Leader:________________
(OPERATION #3 ), ONE OF OPERATORS NOT DELICATED, BUT SUPPORTS 2 LINES Date:______________________
LINE BALANCING GRAPH IN EACH LINE LBR Calculation: _____________
BEFORE LINE BALANCING

• LBR =(24+23+35+26+28)/5*35*100% = 77.7%

40 120%

35
100%
Seconds

30 30
80%
25

20 60%
35
15
28 40%
26
24 23
10
20%
5

0 0%
Operator 1 Operator 2 Operator 3 Operator 4 Operator 5
Cycle time Takt Time Efficiency

32
SCENARIO#3-1 - HOW TO CALCULATE OPERATOR 3-1&2 CYCLE TIME IN LINE BALANCE CHART?

Given:
1. Takt time is 30 seconds
2. Operation #3 Cycle time is 35secs, which is the bottleneck
3. We assigned 2 operators (Operator3-1, Operator 3-2) to perform Operation #3,but one of operators will also
support another line, not dedicated to this line
4. Actual cycle time:
• When Operator 3-1 performs Operation #3, the cycle time is 38secs
• When Operator 3-2 performs Operation #3, the cycle time is 40 secs
Question: how to calculate operator 3-1&3-2 cycle time in line balance chart? and what is new LBR%?
Solution:
1. Takt time is 30s, Operation 3 is bottleneck
2. we assign 2 operators in operation#3, they are 3-1 and 3-2
3. 3-1 is more capable of operation 3, therefore 3-1 will be 100% deployed
4. the output for 3-1 is 3600/38=94pcs
5. the target output is :3600/30=120pcs
6. then 3-2 needs to support 120-94=26pcs
33
SCENARIO#3-2 - HOW TO CALCULATE OPERATOR 3-1&2 CYCLE TIME IN LINE BALANCE CHART?

Question: how to calculate operator 3-1&3-2 cycle time in line balance chart? and what is new LBR%?
Solution(Continued) :
7. Then operation #3 cycle time will be:
8. (94*38+26*40)/120=38.4s
9. Operator 3-1: 30s, Operator 3-2: 8.4
10. Operator 3-2 will be low level engaged in operation#3, the time will be: 26*40=1040
11. % of operator 3-2 involved in operation#3 in 1 hour
=>1040/3600=0.29
12. LBR%= (24+23+30+8.4+26+28)/(30*(5+0.29))=87.8%

34
 IE:_______________________
SCENARIO#3-3 LINE BALANCING GRAPH BEFORE LINE BALANCING Line Leader:________________
BEFORE LINE BALANCING Date:______________________
LBR Calculation: _____________

• LBR =(24+23+35+26+28)/5*30*100% = 77.7%

40 120%

35
100%
Seconds

30 30
80%
25

20 60%
35
15
28 40%
26
24 23
10
20%
5

0 0%
Operator 1 Operator 2 Operator 3 Operator 4 Operator 5
Cycle time Takt Time Efficiency

35
 IE:_______________________
SCENARIO#3-4 LINE BALANCING GRAPH AFTER LINE BALANCING Line Leader:________________
Date:______________________
LBR Calculation: _____________

• LBR =(24+23+30+8.4+26+28)/(5+0.29)*30*100% = 87.8%

3-2 will spend 71% to

35 120%
support another line

30 30 100%
Seconds

25
80%

20 71%
60%
15 30
28
26
24 23 40%
10

20%
5
8.4

0 0%
Operator 1 Operator 2 Operator 3-1 Operator 3-2 Operator 4 Operator 5
Cycle time Takt Time Efficiency

36
 IE:_______________________
SCENARIO#4 - 2 OPERATORS PERFORM ONE OPERATION Line Leader:________________
(OPERATION #3 ), ONE OF OPERATORS NOT DEDICATED, BUT SUPPORTS 2 LINES WITH Date:______________________
NEW BOTTLENECK AFTER REBALANCING LINE LBR Calculation: _____________
LINE BALANCING GRAPH IN EACH LINE
BEFORE LINE BALANCING
• LBR =(24+23+35+26+28)/5*35*100% = 77.7%

40

35
Seconds

30

25 26

20
35
15
28
26
24 23
10

0
Operator 1 Operator 2 Operator 3 Operator 4 Operator 5
Cycle time Takt Time

37
SCENARIO#4-1 - HOW TO CALCULATE OPERATOR 3-1&2 CYCLE TIME IN LINE BALANCE CHART?

Given:
1. Takt time is 26 seconds
2. Operation #3 Cycle time is 35secs, which is the bottleneck
3. We assigned 2 operators (Operator3-1, Operator 3-2) to perform Operation #3, but one of operators will also
support another line, not dedicated to this line
4. Actual cycle time:
• When Operator 3-1 performs Operation #3, the cycle time is 38secs
• When Operator 3-2 performs Operation #3, the cycle time is 40 secs
5. But when we rebalance the operation#3 with 2 operators, then operation#5 will be new bottleneck
Question: how to calculate operator 3-1&3-2 cycle time in line balance chart? and what is new LBR%?
Solution:
1. Takt time is 26s, Operation 3 is bottleneck
2. we assign 2 operators in operation#3, they are 3-1 and 3-2
3. 3-1 is more capable of operation 3, therefore 3-1 will be 100% deployed
4. the output for 3-1 is 3600/38=94pcs
5. the target output is :3600/28=128.5pcs, round down to 128 pcs (based on new bottleneck-operation#5)
6. then 3-2 needs to support 128-94=34pcs 38
SCENARIO#4-2 - HOW TO CALCULATE OPERATOR 3-1&2 CYCLE TIME IN LINE BALANCE CHART?

Question: how to calculate operator 3-1&3-2 cycle time in line balance chart? and what is new LBR%?
Solution(Continued) :
7. Then operation #3 cycle time will be:
8. (94*38+34*40)/128=38.5s
9. Operator 3-1: 28 s, Operator 3-2: 10.5s
10. Operator 3-2 will be low level engaged in operation#3, the time will be: 34*40=1360s
11. % of operator 3-2 involved in operation#3 in 1 hour
=>1360/3600=0.38
12. LBR%= (24+23+28+10.5+26+28)/(28*(5+0.38))=92.6%

p.s. this line capacity is not enough, the expected output is 138pcs ( 3600/26) per hour, actual output is only 128pcs per hour

39
 IE:_______________________
SCENARIO#4-3 LINE BALANCING GRAPH BEFORE LINE BALANCING Line Leader:________________
BEFORE LINE BALANCING Date:______________________
LBR Calculation: _____________

• LBR =(24+23+35+26+28)/5*30*100% = 77.7%

40 120%

35
100%
Seconds

30

26 80%
25

20 60%
35
15
28 40%
26
24 23
10
20%
5

0 0%
Operator 1 Operator 2 Operator 3 Operator 4 Operator 5
Cycle time Takt Time Efficiency

40
 IE:_______________________
SCENARIO#4-4 LINE BALANCING GRAPH AFTER LINE BALANCING Line Leader:________________
Date:______________________
LBR Calculation: _____________

• LBR =(24+23+28+10.5+26+28)/(5+0.38)*28*100% = 92.6%

3-2 will spend 62% to

30 support another line

26
25
Seconds

20 62%

15
28 28
26
24 23
10

5 10.5

0
Operator 1 Operator 2 Operator 3-1 Operator 3-2 Operator 4 Operator 5
Cycle time Takt Time

41
 IE:_________________________
LINE BALANCING GRAPH IN EACH LINE Line Leader:_________________

Line balancing graph display: latest line balance graph with cycle time by operator, takt
time, line balancing rate.

Requirements:

• Chart by operator
• Takt Time
• Cycle Time target
• Cycle Time actual
• Individual Efficiency
• Line efficiency target
• Output target
• LBR %

42
LINE BALANCING GRAPH IN EACH LINE (E.G.)
LBR DATA SECTION Update D1 D2 D3 D4 D5 For clearing per daily cy cle t ime sheet s

Date 24-Nov 24-Nov 25-Nov

LINE BALANCING FORMAT Stage Initial LBR1 LBR2

LINE NO. LBR 47% 67% 86%

C:\Users\iergulfan\Downloads\T-shirt.png
100
Initial ob date 2/25/2021 90
80
Latest Line Balance Cal cul ated Cycle Ti me % dedicated other line TaktTime 100%

Product type Tights 70

60
Style No. S21AWGFX603 50
30 34 35 31 35 31 35 35 35 35 33 33 50%
40 22 21 24 21 27 27 24 24 24
Sewing Smv: 9.668 30 18
20
Target MP: 22 10
0 0%
Target Eff% 75%
Tgt Output / Hr: 102
Takt Time: 35

LBR Rate%
100 Initial Line Balance 1st Day Cycle Time GSD TaktTime

90 74
80 62
Initial LBR% 47.30% 70
60 44 42
50 35 35 39 33 33
Latest LBR% 85.90% 40 30 24 27 27 31 24 24 24
30 18 22 21 21 18
Assigned IE 20
10
0

Supported Supported Operator Operator Suppo Oper Operation Name Machine GSD 1st Day Latest Calculat Initial Calculat Utilizati % Operato Remarks
Operator (1) (2) Name rt Type Cycle Cycle ed Product ed on dedicat r's Eff%
ation
Assign New other Time Time Cycle ion Product (Update ed
Line No.
Maria Yes 1 Cut Excess 4T 24 18 18 18Time 200 ion
200 51%d) other
49% 136%
Jonalyn 2 S/S Crotchl Pnl 3Sd*1 OL4 6+6+6 A7 3T 24 22 22 22 163 163 63% 0% 111%
Mary Fe 3 Jn Crotch to bk+JN bk Rise FS7 17+22 A5 FL 30 21 21 21 171 171 60% 0% 144%
Angie Marie 4 Jn Crotch to bk+JN bk Rise FS7 17+22 A5 FL 30 30 30 30 120 120 86% 0% 101%
Maricel 5 JN Lwr Insert to Bk Mesh FL 35 24 24 24 150 150 69% 0% 148%
Salito Yes 6 JN Upr Sd Pnl to Bk Mesh FL 35 21 21 21 171 171 60% 40% 169%
Carmelodie Elva Melody 7 JnFnt Rise FS7 17+22 A5 + Hem Leg Opng Rnd FS7 25 A5 + aPE Att Exposed Elastic to FL 19 18 18 34 200 104 98% 0% 84%
Janet 8 WBSd
JN Rnd
Pnlw/Holder MC6 80 A5
to Bk (Left) FL 32 27 27 27 133 133 77% 0% 118%
Raul 9 JN Sd Pnl to Bk(Right) FL 32 27 27 27 133 133 77% 0% 118%
Marilou 10 JN Leg Outsm FS7 80 A5(LEFT) FL 45 35 35 35 102 102 100% 0% 128%
Charlita 11 JN Leg Outsm FS7 80 A5(RIGHT) FL 45 31 31 31 116 116 89% 0% 144%
Crestina 12 JN Leg Insm Cont FS7 145 A5 FL 60 62 62 35 58 102 100% 0% 171%
Crestina Rogelio LinLen 13 JN Leg Insm Cont FS7 145 A5 + Hem Leg Opng Rnd FS7 25 A5 FL 60 74 74 31 48 114 90% 0% 97%
Rose Mary 14 Att Lbl to W/L SN 13 24 24 24 150 150 69% 0% 56%
Lendy 15 Att Attaca Lbl to Mn Lbl 4T 13 24 24 24 150 150 69% 0% 53%
Lendy 16 Cut Excess 4T 18 24 24 24 150 150 69% 0% 75%
Severino 17 aPE Att Exposed Elastic to WB Rnd w/Holder MC6 80 A5 2CS 32 35 35 35 102 102 100% 0% 93%
Elva 18 aPE Att Exposed Elastic to WB Rnd w/Holder MC6 80 A5 2CS 32 44 44 35 81 102 100% 0% 93%
Carmelodie 19 Hem Leg Opng Rnd FS7 25 A5 4CS 43 42 42 35 85 102 100% 0% 122%
Rogelio 20 Hem Leg Opng Rnd FS7 25 A5 4CS 43 39 39 35 92 102 100% 0% 122%
Marciana 21 Btk*5(Wb*1&Pkt Opng*2&Leg Btm*2) BT2 BK 34 33 33 33 109 109 94% 0% 104%
Liezyl 22 Fld & BS Hangtag to Wb*1 BS 13 33 33 33 109 109 94% 0% 38%
43
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