IMP-04 — LINE BALANCING

Run the line to demand, not to drama.

Takt time from real demand, work elements timed, station loads rebalanced — so the line produces what the day needs without overtime at one end and idle hands at the other. Usually the fastest payback in the improvement kit.

Scope this engagement All four disciplines

WHAT YOU GET

The deliverables, plainly.

LB-01

Takt & element study

Demand converted to takt; every work element timed at the station, with the variation captured, not averaged away.

LB-02

Rebalance & trial

Elements redistributed against takt in paper trials first, then live pilots — the crew sees the maths before the change.

LB-03

Standard work & andon

The new balance held by standard work and a simple signal when a station drifts — so the balance survives absence and turnover.

SEQUENCE — HOW IT RUNS

STEP 01

Demand & takt

What the line must produce, converted to seconds.

STEP 02

Time the elements

Every task, every station, real cycles.

STEP 03

Rebalance & pilot

Paper trial, live pilot, adjust, lock.

STEP 04

Hold the balance

Standard work, cross-training matrix, drift signal.

TYPICAL ENGAGEMENT

2–4 weeks per line

WHERE IT FITS

Overtime chronic at some stations, idle time at others

OUTPUT

Balanced stations, standard work, +15–35% typical throughput

Q&A

The aim is throughput with the same crew — freed capacity goes to demand you currently turn away or hours you currently pay as overtime. Clients who cut heads after a balance usually lose the balance; we say so up front.

Yes — scoped on a call, quoted fixed in writing. Improvement engagements also state the meter we'll measure the gain on, so success is defined before we start.

NEXT STEP

Put a number on the constraint.

A thirty-minute call, the meter agreed, and a fixed-price engagement in writing.

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