1st Edition

The Basics of Line Balancing and JIT Kitting

ISBN 9781439882375
Published April 20, 2012 by Productivity Press
85 Pages 70 B/W Illustrations

USD $24.95

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Book Description

Accessible to the Lean novice and shop floor employee, The Basics of Line Balancing and JIT Kitting explores line balancing and the pre-assembly of components into a finished product in a just-in-time fashion (JIT Kitting). It explains how to use time studies, develop yamazumi charts, discover and eliminate waste, balance your line, and create new standard work content for the shop floor.

The book facilitates a clear understanding of the seven deadly wastes (muda) as well as what you can do to eliminate them from your facility. Describing the purpose and use of standard work, it explains how to properly staff work cells and how to develop flex plans for fluctuations in demand using this data. The first few chapters explain how to determine takt time and how to use that information along with time studies to identify when you are not meeting customer demand.

The chapters on JIT Kitting explain how there are other advantages to kitting besides eliminating waste and increasing productivity. The book explains how you can use JIT Kitting to improve quality by having the parts available and limiting the options of numerous parts to the operator. It also provides the understanding needed to ensure the right parts are installed, thereby correcting issues with the build of materials.

Table of Contents

Where Are My Hidden Costs?

Understanding Your Rhythm

Genchi Gembutsu

     "When in Doubt, Throw It Out."
     "A Place for Everything and Everything in Its Place."
     "Keep It Clean."
     "This Is What Is Expected Every Day in Every Area."
     "Audit the Process to Ensure Sustainability."

Line Balance and Yamazumi
Variable Work Content

Leaving the Waste In
Rebalance Removing the Waste

Flex Plans

Standard Work

JIT Kitting
Kit Specifics
     What Type of Kit?
Material Delivery
     What Type of Transportation?
Workstation Design
     Designed for Kits, Tools, and Ergonomics
Line-Side Layout
     Layout for Station and Tugger Delivery
Supermarket Design
     Size and Layout of the Supermarket
Pick Lists
     Pick Lists and Heijunka
Material Handling Takt Times
     Material Handling Is Now on a Takt Time
Refining the Process
     Correcting Mistakes and Anticipating the Crash Period

High Mix and Complexity


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Beverly Townsend is a Lean manufacturing manager and artist from Kentucky. She is an expert in Lean, with years of experience starting at Toyota. She also holds chairman and president’s awards for her Lean achievements in operation excellence for JIT kitting and waste elimination. Her experience involves teaching and mentoring in Lean as well as implementation. Her efforts have transformed facilities into benchmark plants, as well as sustained business and growth.

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Author - Beverly  Townsend

Beverly Townsend

Lean, Ingersoll Rand
Lexington, KY,

Learn more about Beverly Townsend »