1st Edition
The Basics of Self-Balancing Processes True Lean Continuous Flow
Conventional Assembly Line Balancing
Paced Lines
Manual Assembly Lines
Level Loading
Shortcomings of Level Loading
WIP Buffers
Slowest Operator/Station Sets the Pace
Variations in Yield and Cycle Time
Absent Operators
Inflexible, Difficult-to-Adjust Output
Silo Mentality
Repetitive and Monotonous Work for the Line Workers
Moving Beyond Level Loading
A New Paradigm
Self-Balancing
Rules to Standardize Self-Balancing
Rule 1: Keep Building Progressively Until Someone Pulls from You
Rule 2: When the Downstream Operator Pulls from You, Walk Upstream to the Next Operator and Pull from Them
Rule 3: If You Catch Up to Someone When Moving Downstream, Wait
Rule 4: Don’t Leapfrog; Everyone Stays in Their Position
Rule 5: Communicate, Communicate, Communicate!
Dealing with Fumbles
Standard Conditions for a Fumble
Nonstandard Conditions for a Fumble
Fumble Rules
Rule 1: Encountering a Fumble When Moving Upstream
Rule 2: Encountering a Fumble When Moving Downstream
Rule 3: Returning to a Fumble
Batch and Off-Line Processing
Backbench
In/Out Tray
Guidelines and Rules for Backbench Operations
Rule 1: Frontline Operators Leave the Line to Perform Backbench Operations on Demand
Rule 2: Operators Communicate When Leaving for the Backbench
Rule 3: Reenter the Frontline in the Same Position
Types of Loading and Unloading
Subassembly Feeder Lines
Rule 1: Going Down the River
Rule 2: Going Up the River
Rules for Subassembly Feeder Line Operators
Rule 1: When Frontline and Feeder Line Are Synchronized
Rule 2: Encountering a Fumbled Subassembly
Debugging the Line
Bottlenecks
SWIP Inventory
SWIP Increasing
SWIP Decreasing
Additional Debugging
Horizontal Arrangement of Parts and Tools
Benefits and Potential Disadvantages of Horizontal Part and Tool Presentation
Additional Rows of Parts for Mixed-Model Lines
Quick Product Changeover of a Cell
Cell Designs
Cell Design Considerations
Safety
Walking Distance
Part-Travel Distance
Cell Layouts
Basic Cell Shapes
Cells with Off-Line Processing
Station Setup
Right-Sized Stations
Vertical Space
Standing Height
Standing Surface
Conclusion
Index
Biography
Gordon Ghirann
Instead of explaining merely the typical approach that seeks to balance the work and operates strictly according to takt time, Gordon’s method takes advantage of the ‘human element’ and releases the full potential of the employees. … Self-Balancing surfaces barriers to flow and provides a framework for the supporting management support system. …Until now, there was no source for this powerful concept outside of some limited research on the web. Gordon, however, has probably experimented more with Self-Balancing than anyone else, so I’m very excited that he has finally brought this powerful concept to you.
—Kirk Paluska, Lean Transformations Group
