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

1. 5 Levels of Control – Achieving
‘Perfect Flow’
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2. Achieving Perfect Flow – the 5-Levels of Control
Using these developed principles, it is possible to get close to
achieving perfect flow
1. Equipment control and monitoring - automation
2. Speed settings – line balance, V-curve
3. Optimised conveyors – speeds intelligently controlled
4. Cascade control – elimination of response times
5. Automatic linked speed control

3. Level 1 – Equipment Evaluation
• All equipment automatically controlled, no
manual intervention
• Equipment breakdowns are clearly indicated
to the operator, the root-cause is identified
and the operator has a procedure to restart
• Variable speed control is possible (machines
& conveyors)
• Machines networked to enable linked speed
control
• Any manual adjustments will time-out and
revert to nominal
• Auto splicing technology in use where
applicable

4. Level 2 – Speed Settings, V-Curve
• The critical machine runs at its rated
speed
• Machine speeds are set based on
the V-curve
• Speeds can not be tampered with
• Speeds are calibrated regularly
• Speeds modulate based on
conveyor states
• Ramp up times are optimised
• There is no machine “hunting”

5. Level 3 – Optimised Conveyors
• Conveyor speeds are controlled relative to machine speeds
• Speeds are set based on documented trials
• Line is as empty as possible when in lack
• Line is as full as possible when in build back
• Dynamic accumulation is optimised

6. Level 4 – Cascade Control
• Restart times are minimised by applying cascade control
• Conveyor sensors are over ridden during a restart
• Multiple restarts are factored into logic to protect the line

7. Level 5 – Linked Speed Control
• The line speed is set and dictated by the critical machine
• This speed is “broadcast” to all other equipment
• Nominal running is represented by all equipment running at the same speed
• A recovery situation results in a V-curve scenario
• Dual legs split the load and run at maximum when one leg is down