Unbalanced Machine Loads
Machine A overloaded (70% util), Machine B moderate (55%), Machine C underutilized (30%). Work was distributed arbitrarily by procedure rather than by machine capacity.
What Became Visible
Machine utilization analysis revealed significant imbalance. Bottleneck was overloaded Machine A. Available capacity on Machines B-C was unused. Work redistribution was possible.
Work Rebalancing
Work reassigned from Machine A to underutilized Machines B-C, balancing loads. Machine A capacity freed; overall throughput increased without new equipment.
How it worked: Load balancing analysis revealed available capacity. Procedure redesign redistributed work to available capacity.
Results
all machines toward balanced level
from balanced loading
enabling sustainability
annual throughput gain
Load imbalance indicates available capacity. Rebalancing work toward available capacity improves throughput without equipment investment.
Operational Reality
The facility had unused capacity on some machines. Rebalancing revealed and activated that capacity.