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Work Rebalanceby
Moving Line SOS
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Interaction between Static & Moving Objects
The Moving Line SOS is the tool used to document the standardised
work of operators who work on a conveyor based moving line, for
example the areas General Assembly and Tapping.
Advantages of the Moving Line SOS:
A summary of the current best method A visual control tool to ensure the operation is being performed
according to existing standards
A basis for problem solving and line rebalance Makes visible the waste in a process
A training tool to instruct new operators
Confirms the Weighted Average Cycle Time for the process
Moving Line
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Calculate the Takt Time
Confirm the Actual Takt Time
Calculate the Operation Rate
Confirm the start position for each process
Confirm the stop position (FPS) for the conveyor
Confirm volume status (volume gate) Confirm the quality status (quality gate)
Step 1 - System Fundamentals
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1st - Element Break
2nd - Create Element Sheets
Identify the Elements Create Element Sheets
Time the Elements
Step 2 - Grasping the current condition
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Create a Moving Line SOS
Identify the Walking
Confirm option impact
Calculate Weighted Average Cycle Time & Element Time Complete Work Position section
Complete Team Member Movement section
Complete Work Distribution section
Create a Moving Line SOS
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Create the Moving Line SOS
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The MLSOS has eight columns for showing the different models or
options that may impact one particular process. This may be different
for each workstation, and should be based upon the current schedule.
Simple Example - 8 or less possible variations
Model / Option Mix: KIT 14 F = 60% KIT 14 C = 36% KIT 14 Other= 4%KIT 17 E = 60% KIT 17 B = 36% KIT 17 Other= 4%
KIT 28 D = 78% KIT 28 B = 18% KIT 28 Other= 4%
Calculate the possible options using a tree:-
Confirm the Option Tree
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Simple Tree
1 5
2 6
3 7
4 8
Handwork / Model
15 15 15 15
2 2 2 2
185 185 185 185
14 8 8 4
42 42 42 42
Model 11
Other
Model 4
Model 8
4
3 Option for kit 14
1
Work
Element
Registered
Number
1
Ass embly of Kit 14
11
2
Read Manifest / Pickup Kit 14 and Components
8 other
2 3 4S
i
m
b
o
l
S
t
e
p
1
Assembly L322 LHD
2
Element Name
Operation WS3 - 5
Group / Team
3 Ass embly of Kit 17
5
4
Model Description
60%
60%
60%
36%
36%
18%
4%
4%
4%18%
438 430 432 424 0
11 11 11 11 0
eg
Cycle Time sec . 441 '' 443 ''
0 ''
0 ''
77 ''
18%
80 '' 17 ''
78 '' 17 ''
Volume % 60%
269 ''
Weightet Average Element Time
Weightet Average Cycle Time
263 ''
79 ''
18% 0%4%
435 '' 0 ''449 ''
ctuaa t me 460
Total Element Time / Walking by Model sec .
Mark which model is shown in each column
and fill in the volume %
Focus on the most representative models
(higher volume)
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Document the element time, cycle time and actual
takt time for every option shown on the SOS
Show Cycle Times
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High workload due to Model or Option mix can cause unevenness.
This unevenness makes it more difficult to utilise our manpower fully.
Team memberA Team memberB Team memberC
Balanced!
Basic Car With maximumNo. of Options With Sunroof+ Side Air BagsWith Sunroof
Wait Time!
Over cycle
Unevenness (Mura)
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1 5
2 6
3 7
4 8
Handwork / Model
15 15 15 15
2 2 2 2
185 185 185 185
14 8 8 4
42 42 42 42
Model 11
Other
Model 4
Model 8
4
3 Option for kit 14
1
Work
Element
Registered
Number
1
Assem bly of Kit 14
11
2
Read Manifest / Pickup Kit 14 and Com ponents
8 other
2 3 4S
i
m
b
o
l
S
t
e
p
1
Assembly L322 LHD
2
Element Name
Operation WS3 - 5
Group / Team
3 Assem bly of Kit 17
5
4
Model Description
Final Assembly Options Matrix
Moving Line
A
A
A
A
A B
BA
B
D
E
D
B C C D D
B C CD D
The operator sees in the manifest the option (model) to build.
By checking the Final Assembly Options Matrix he /she finds
the options of the kits to assemble.The operator can check the build sequence consulting the
ML SOS (see step column in the ML SOS)
The Team Leader can see if the operator is following the
right build sequence and times by comparing the activity ofthe operator with the ML SOS
Manifest
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Create Analysis Tools
Create a Work Distribution Chart
Create a Work Position Summary Sheet
Create a Location Map
Create a Work Area Map
Step 3 - Evaluation
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Show the Takt Time
Show the Actual Takt Time
Show the Weighted Average Cycle TimeShow the Weighted Average Element Time
TT
ATT
Element
Time
Cycle
Time
Process A
Create a Work Distribution Chart
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The Work Distribution Chart is not a NUMMI wall!
The function of the chart is to capture the "Big Picture" and not
to function as a tool for detailed line balancing.
Identify Waiting TimeIdentify Overburden
(Bottleneck)
Function of the Work Distribution Chart
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Confirm the Work Positions -
Confirm the # of Trips - Confirm the # of Locations
Create a Work Position Summary Sheet
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Create a Location Map
4.2
C W k A M
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Conflicts in team member movement
Working Area Map:
Current Condition
Direction of conveyor
Create a Work Area Map
Conflicts
367 5 4 2 111 89
13 15 17
1012
14 16 18 19 20 21 22 23 24
St 4 I f Fi l Sh
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- Achieve volume- No repair- No scrap- Full utilisation- Short lead time
......
What are theproblems?
What are the
current conditions?
Step 4 - Image of Final Shape
St 5 R d C l Ti
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One Point CIP ActivitiesFocus:
o Simple
o Low Cost
o Easy to implement
o Change the environment
Step 5 - Reduce Cycle Times
Theme
Before
After
Problem
Effect Cost
Material Location
Walking for Material
Reduction of walking 0
Stn 8L Stn 8R Stn 9L Stn 9R Stn 10L Stn 10R Stn 11Harness
Pick Total
Number of CIP
Ideas13 7 7 9 2 7 3 6 54
Cycle Time
Reduction0.43 0.32 0.31 0.58 0.12 0.64 0.20 0.10 2.70
Original Cycle
Time3.17 2.63 3.77 3.36 3.89 4.23 2.24 3.48 26.77
New Cycle Time 2.74 2.31 3.46 2.78 3.77 3.59 2.04 3.38 24.07
WS 1 WS 2 WS 3 WS 4 WS 5 WS 6 WS 7
St 6 A ti / R b l
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Look for:-
Dedicated equipment.Low average cycle time.
Single spread elements.
High locations.
Small elements.
This is done by transferring work
out from process to fill up theothers.
Establish a
target process
Consider the benefit achieved
from transferring workbetween processes
The objective is to gather
the available wait time
into one process.
Step 6 - Auction / Rebalance
Pickup
WiresCable
ChannelU.S
Splices 1/2Tapping
X 209Tapping
C. ChannelAssembly
KIT 10A
KIT
1APickup
KIT 1AAssembly
KIT 1A
Ground
Splice X1
Cover
Conn. A1
Step 6 Auction / Rebalance
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X
X1
4
23
5Develop alternative combinations to reduce waste (Auction)Develop proposals for different combinations.
Trial and simulate.
Evaluate the new work position summary sheet.Make a new location map and compare to the old.
Create a draft New Moving Line SOS.
Confirm in a line trial.
Does it actually work ?. => Fix the final proposal
Finalise the new Moving Line SOS.
Re-establish the Work Element sheet folder.
Step 6 - Auction / Rebalance
Step 7 Result Confirmation
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process cycle times
No. processes x Act. TTx 100% = 100
AfterBefore
1260 = 60%
35 x 60
1260 = 66%
32 x 60
Takt Time
Act TT
Cycle time
Frequency Line Station
10
9 Example:
8
7
6
Old 5
4
3 6 10 14
2 5 9 8 11
1 2 12 7 3 1 13 4
0 1 2 3 4 5 6 7 8
1 3 2 8 1
2 4 13 9
3 5
4 6
New 5 9
6 10
7 11
8 12
9
10
Consider for evaluation of improvement:
Location map spread.Trip frequency.
No. of processes.
Percentage of member cycle time to Actual takt time.
Step 7 - Result Confirmation
7
3
Team Member Balance Chart
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Team Member Balance Chart