Industrial Engineering

Maximum efficiency improvement of production processes through optimal line-balancing

Until recently, production control at many companies was based primarily on estimates and past experience. As a result, serious discrepancies often occurred between actual working times and calculated operating times – thereby making cost improvements either ineffective or of limited use. Today however, Ingenics offers a practical solution: With the aid of proven industrial engineering tools such as line-balancing, your production processes can now be optimized for long-term operations and maximum efficiency increases can finally be achieved.

During its efficiency improvements of production systems, Ingenics has become well known by using its comprehensive approach. “By individually tailoring our solutions to each customers’ individual needs and requirements we can provide them with consistent support: from the initial analysis to the final implementation,” explains Andreas Hoberg, a recognized industrial engineering expert and partner at the Ingenics AG.

Bottom-up analysis for maximum transparency
In most cases, CIP projects usually start with a bottom-up analysis of the production lines to create maximum transparency. In close cooperation with the company’s most experienced employees, all of the actual production stages are reviewed and analyzed.

Here, the most decisive factors we examine are: the calculated operating times, employee training, as well as possible operating restrictions and breakdowns.

Practical implementation using PERT chart techniques (network planning)
The next step of a typical CIP project then involves the practical implementation of the desired improvements. Based on the results of the bottom-up analysis, proven PERT chart techniques (network planning) are used to identify all logical operating relationships and relevant technical limitations of a specific product. This then allows us to determine the best possible solution for maximum efficiency improvements throughout the production.

Summary
“In the end, this approach lets us identify critical pathways, potential bottlenecks and essential production processes that require optimization,” adds Andreas Hoberg. “Plus, network planning also serves as a basis for reliable project controls and schedule monitoring.”

As a result, future production processes can then be precisely defined – including all required capacities, time frames and cost factors. Thereby providing everything needed for optimal line-balancing of the entire production operation and maximum efficiency improvements.
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