Page 317 - Six Sigma Demystified

Part 3 S i x S i g m a To o l S 297

Level Loading

Level loading is a lean tool used to balance the flow of orders throughout a
process.

When to Use

Improve Stage
• To balance the flow of orders through a process and reduce in-process
inventories

Methodology

Some prerequisites for successful level loading include

• Standardization of work instructions
• Cross-training so that employees can be shifted to meet increased demand
or address process problems
• Transparency so that operational personnel detect and respond to shifts in
demand or process problems as soon as possible (Transparency, or visual
control, has been found to decrease the reaction time to waste, foster re-
sponsibility, and aid in problem solving.)

To balance the process steps,

• We first calculate the takt time. Takt is the German word for “metronome,”
and it is used to indicate the desired rhythm of the process.

• Takt time = demand (units)/available resource (hours) For example, if the
product has an average demand of 64 units per day, and the cell works 16
hours per day (two shifts), then the takt time is calculated as 15 minutes
(i.e., 4 units per hour).
• The takt time is posted at the cell, and the resources (machines and per-
sonnel) at each step within the cell are balanced so that their cycle time
equals the takt time.
• While we usually can design the process and allocate standard resources
for any process to meet its standard takt time, we recognize that a shift in
demand will shift the takt time requirements. One way to accommodate
the takt time adjustment is to shift resources.