Hidden Bottlenecks
One slow station drags throughput for the entire line.
AI Line Balancing: See Every Bottleneck. Balance Every Line.
AI line balancing from video: film your line, get a Yamazumi chart against takt, and test rebalancing scenarios before you change anything.
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The Challenge
Why Lines Stay Unbalanced
Why line balancing is hard to keep up with by hand.
Manual Yamazumi
Building one in Excel is a half-day exercise per scenario.
Stale Takt
Demand shifts but staffing stays the same.
How it works
How AI Line Balancing Works
From video upload to a balanced line recommendation in three steps.
1. Film the Line
Record every station on the line, from the start of each cycle to the end.
2. Auto-Yamazumi
AI splits the work into elements, assigns them to each operator and charts them against takt.
3. Rebalance
Move elements between stations in a simulation and see the new balance before changing the line.
Features
AI Line Balancing in One Workflow
Built for industrial engineers, CI leads and supervisors. No AI expertise required.
Feature 01
Auto Yamazumi
Each station's cycle time becomes a stacked bar of elements, split into value-added, semi-value-added and non-value-added time.
Auto-generated stacked bars per station
Element-level color coding tied to time study data
Instant imbalance flags against Takt time
Feature 02
Takt Overlay
A takt line sits over every Yamazumi and recalculates when demand or shift pattern changes.
Real-time Takt recalculation on demand changes
Overlay updates across all stations simultaneously
Instant over/under-Takt visibility
Feature 03
What-If Simulator
Drag an element to another operator or station and the balance redraws. Save each idea as a scenario with the minutes and cost it saves.
Drag-and-drop element reassignment
Real-time balance and Takt impact
Saved scenarios with minutes and cost saved
Before-and-after study comparison
Feature 04
Operator Loading
Each operator's utilization against takt, with bottlenecks and idle time in one view.
Per-operator utilization %
Operator vs. station comparison view
Bottleneck and idle-time detection
Feature 05
Mixed-Model Support
Balance multi-product lines by the real demand mix and see each station's combined load.
Weighted demand-mix balancing
Multi-product line support
Combined station load across models
Feature 06
Constraint Awareness
Lock elements to a station for safety, tooling or skill, so proposed moves are realistic.
Element-to-station locking
Safety, tooling, and skill constraints respected
Realistic rebalancing suggestions only
From video
Line balancing from one video of the line
The AI time study does the timing; you do the balancing.
Film the line
Record the stations on a phone, tablet or fixed camera. No special hardware required.
Upload and tag
Drop the video into LeanSuite, pick line balancing and tag the line.
Get the Yamazumi
The AI times each operator's elements and charts every station against takt.
Rebalance and save scenarios
Drag tasks between operators to flatten the Yamazumi and save each scenario with the minutes and cost it saves.
What you get back
- Per-element timing with statistical variance
- Yamazumi chart against takt
- Side-by-side current vs. future state
- What-if rebalancing simulator
- Quantified labor productivity gain
- Findings that become Kaizens in one click
Why It Matters
Why Teams Choose It
No hand-built Yamazumi charts or changes tested on the floor: rebalance by dragging elements, and turn findings into Kaizens in one click.
Higher Throughput
See the gain in the Yamazumi before anything changes on the floor.
Faster Re-balancing
What-if scenarios without touching the floor.
Standard Output
Yamazumi charts every plant manager can read.
FAQs
Frequently Asked Questions
Line balancing spreads work across stations so each one's cycle time sits at or just under takt, with no bottleneck and no operators left waiting.
Upload a video and the AI time study breaks each operator's work into elements, charted as a Yamazumi against takt. Drag elements between operators and compare scenarios before changing the line.
Yes. Compare studies by operator or for the whole line, and compare scenarios by minutes and cost saved.
Yes. Findings suggest what to eliminate, combine, rearrange or simplify, and each can become a Kaizen in one click.
Up to 24 stations per line in a single analysis, more on request.
Yes. Adjust takt or the shift pattern and the Yamazumi re-simulates in under a second.
Yes. Weight elements by product mix and balance for the real production schedule.
Yes. Pin elements that must stay put because of tooling, safety or skill constraints.
FREE RESOURCES
Free templates and tools
Not ready for software yet? Start with these free resources.
- Time study sheetTime each element over 10 cycles and work out the average, lowest repeatable and standard time. Excel does the sums.
- Standard work sheet templateTakt time, each element's manual, machine and walk time on a time chart, key points and standard WIP.
- Standard work combination tableOne operator's manual, machine, walk and wait time on a time chart against takt, with machine cycles and a process capacity sheet.
- Bottleneck analysis worksheetEffective capacity per station from cycle time, parallel units, availability and yield, the bottleneck, takt and utilization, a queue cross-check and the five focusing steps.
- Heijunka box planner (production leveling)Weekly demand turned into containers a day, takt, pitch and slots, a leveled sequence of products and the heijunka box, with a check that the changeovers fit.
- Process capacity sheet templateEach machine in a part's routing with manual, auto and tool change time, its capacity per shift, and the step that limits the cell against demand.
- Chaku-chaku line plannerPlan a load-load cell: time each machine, load and walk, check that every machine is ready when the operator comes back, compare the cell cycle with takt and size the crew.
- Line balancing calculatorLine efficiency, balance delay and the minimum number of stations from station times and takt.
- Takt time calculatorThe pace a line must hit to meet customer demand, from shift time, breaks and daily demand.
- Bottleneck calculatorThe step that limits your line, from each step's cycle time, machines and uptime, with daily capacity and the gap to demand.
Ready to see Line Balancing in action?
Bring one video of your line and see the Yamazumi, scenarios and findings it produces.