Line Balance Optimisation is about maximising output at the critical machine by reducing or eliminating impact of upstream or downstream machine stoppages.

1. Line Balance Optimisation (LBO)
Overview
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2. Introduction
What is “LBO”?
“It is the process of optimising line performance
through the effective use of automation and control
philosophies”
Where is it applicable?
On any automated, multi-machine, production line
where equipment speeds can be varied and spare
capacity exists within the conveyor / transport
system

3. The Basic Rules
There are three very simple rules to follow when considering
Line Control:
1. Maintain the Critical Machine in a running state, ideally
at its optimum speed
2. If upstream or downstream equipment fails, maintain the
Critical machine in a running state for as long as
possible
3. If the Critical Machine has stopped, restart it as quickly
as possible

4. V-Curve Explained
Production lines are regularly designed and setup by using the practice of
applying a “V-curve”.
In reality, this more often resembles a tick () in shape.
Critical machine
Filler
30,000 uph
Packer
36,000 uph
Labeller
33,000 uph
Depalletiser
33,000 uph
Palletiser
40,000 uph
Normally Full
conveyors
Normally Empty
conveyors
Example Production Line:
(generic bottling ine shown)
Uph = Units per Hour

5. Vision of Perfect Flow
To set us a target to aim for, let us envisage what “perfect flow” would
look like:
• All equipment on the line runs in automatic without any manual
intervention
• During normal running conditions, the line speed is matched to that of
the critical machine
• All equipment stops are clearly indicated and identifiable
• Minor stops to upstream and downstream equipment does not affect
the critical machine
• Major stops affect the critical machine for the minimum period
• The critical machine restarts almost instantaneously after a stoppage

6. Perfect Flow, the Multiple Hour-glass Model
Explanation of Model:
• Imagine a number of hour-glasses stacked on top of each
other
• Each “bubble” represents a section of conveyor
• The “holes” between bubbles represents the equipment on
the line
• The smallest hole represents the critical machine
• The size of the hole represents the max speed of the
equipment
• The coloured (orange) area represents product & its flow
• (The conveyors are all shown same size though in reality are
likely to vary)
• Attempting to run downstream equipment faster than the
critical machine results in self-starving, “hunting” and
equipment start-stopping.

7. Perfect Flow, the Multiple Hour-glass Model
Normal Running Machine Stopped
Stop
Machine Restarted
Restart