Mix-Balancing: Greater Efficiency in Variant Production
As differences in production times increase, a max-balancing becomes increasingly inefficient. Every variant shorter than the cycle time creates idle time, which comes at the expense of both efficiency and quality.
In this white paper, you’ll learn how to successfully transition to a mix-balancing in five clear steps. Efficiency gains can quickly reach ten, twenty, or more percentage points.
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Insights From This Whitepaper
Why Max-Balancing Is Reaching Its Limits
- Why Increasing Spread in Production Times Leads to Downtime and Losses in Efficiency
- Why any variation below the cycle time compromises efficiency and quality
- The Role of Open Station Boundaries and Drift as Compensatory Mechanisms
How To Successfully Transition to a Mix-Balancing
- Why a drift limit is necessary and what happens when it is exceeded
- How sequencing rules, such as the density rule smooth out the order program
- Why line balancing and rules must be continuously adjusted to the mix of variants
The Benefits of Mix-Balancing
- Efficiency gains of 10, 20, or more percentage points
- Why Sequencing and Capacity Simulation Prevent Bottlenecks
- That the line remains efficient even as the mix of variants changes
„The cycle time is not a rigid limit that every single order must adhere to. The key is that the average utilization rate remains below this threshold. If a job exceeds the cycle time, the excess work is completed in the following cycle, rather than designing an entire station to accommodate the worst-case scenario. This turns wasted idle time into usable capacity. “
- 20sec – 1h cycle time
- 15 – 1.000 workplaces
- 100 – 2.500.000 tasks
- 10-1027 order variants
Is This Whitepaper Relevant for You?
This content is of particular interest to you if you:
- Plan multi-variant assembly lines
- want to make your balancing more efficient and transparent
- want to simulate and optimize production planning to a greater extent
- Reduce planning time and better secure decisions
- are looking for modern software for production planning
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Whitepaper