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Line Balance Optimisation (LBO) Overview

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complete manufacturing

improvement


• Production lines are designed around a CRITICAL MACHINE which is the slowest & typically most expensive item on the line - normally a filler / blow-fill

• Line performance is measured based on the performance of this machine i.e. if it is running, the line is running, if it is slow, the line is slow

• All other equipment should have the ability to run faster – than its neighbour (towards the Critical Machine)

• Plotting these speed values creates what is known as a V-curve (normally more like a tick )

• Lines have in-built accumulation to prevent machine stoppages immediately impacting the upstream machines

Production Lines


There are two ways of improving production line uptime (due to unplanned stoppages):

• Prevention: Improve the machine efficiency(increase MTBF, reduce MTTR)

• Minimise the impact: Line Balance Optimisation

You will have been targeting the machine efficiencies since day 1

“Machines will always break down or require material replenishment. Optimising the line balance minimises the impact when this happens”

Targeting Production Line Performance


What is LBO?• A process to optimise line efficiency through automation and control

Where does it apply?• On any production line that is - automated, multi-machine, where equipment

speeds can be varied and spare capacity exists on conveyors

Why do it?• It can get you up to 10% Efficiency for a low cost with little to no change of

behaviours

Line Balance Optimisation (LBO)


Example:

A filler stops in backup 3 times an hour for an average of 2 minutes per stoppage.What are the maximum potential savings available?

(3 x 2) = 6 minutes per hour ≈ 10% Line efficiency

This 10% is what we are targeting to improve

Therefore 1% Line Efficiency per Hour = Sec36

‘Size of the Prize’


MachineMachine

ConveyorConveyor

Bottle/CanBottle/Can

Our model of “perfect flow”:

LBO – The Approach

• Audit to compare our model to the line

• Variances = opportunities

• Optimise opportunities through actions

• Prioritise based on value and return

An optimised line will: Run at its rated speed

Operate in automatic with minimum operator input

Be more resilient to equipment stoppages

Restart faster (potentially instantly) after a breakdown

Recover to normal production conditions quickly

An optimised line will: Run at its rated speed

Operate in automatic with minimum operator input

Be more resilient to equipment stoppages

Restart faster (potentially instantly) after a breakdown

Recover to normal production conditions quickly


There are 3 Basic Goals:1. To maintain the Critical Machine in a running state at its rated

speed

2. When upstream or downstream equipment fails, maintain the Critical machine in a running state for as long as possible

3. When the Critical Machine stops, restart it as quickly as possible

The Goals


Areas of Focus(to achieve the 3 Goals)


Equipment is assessed in 2 main categories:

Indication & Response Times:

• Are faults clearly indicated?• Can they be seen by the operator? (line-of-sight)• Do they identify the root cause enabling quick repair?

Automation

• Is equipment networked?• Are machines & conveyors capable of variable speeds?• Minimal operator intervention

Equipment Review


The purpose of focusing on dynamic accumulation (empty conveyor space) is to create as large a buffer as possible. This buffer can then be used in the event of a breakdown.

M1 M250%

M2

50%

100%M1

Non-optimised Line:

Optimised Line: The critical machine continues running for longer on an optimised line

The conveyors are TRANSPORT systems, NOT STORAGE systems.

Dynamic Accumulation


The purpose of focusing on cascade control (automatic restart signals) is to get the critical machine running again ASAP

M1 M2

M1 M2

Non-optimised Line:

Optimised Line: The critical machine restarts quicker on an optimised lineInstant

Often > 60 secs

Guideline: After a restart, if there is a gap on the conveyor between the last product and the first, there is scope for improvement

Cascade Control


Some Examples of Opportunities


Filler Pasteuriser

Filler stopped in Buildback due to Pasteuriser fault

Opportunity: Use available space to keep critical machine running longerSpace for 1300 extra bottles = 1m 05s Filler run time Example: 1 stop per hour = +1.8% Efficiency

Conveyor Space


Opportunity: Keep machine running longer when other machine stopsExample: 60s longer x 2 stops per hour = +2.5% Efficiency

Conveyors are full in normal running state

Buffer Space


Gaps on conveyor when Filler restarts after buildback

Opportunity: Restart Filler quicker after downstream machine restartsExample: 30s earlier x 3 stops per hour = +2.5% Efficiency

Cascade Control


Example of Results AchievedWith Line Balance Optimisation


Example of Results from a Customer


Thank youQuestions?

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“LBO showed us quick opportunities to gain up to 4% OEE improvementPlant Manager, Friesland Campina

“LBO helped us identify more than 5% OEE gainProduction Manager, AG Barr

“By implementing actions out of the LBO audit increased the USLE of our line from 69% to 77%Country Manufacturing Manager, Coca-Cola SABCO

“The implementation of LBO allowed the site to optimise line OEEFactory Operations Manager, Coca-Cola Enterprises

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