Step 7 – Balanced Workload

Lean Expert Training Online

Welcome to lesson nine in the Level 3 – Lean Expert Training Course.

To see detailed instructions explaining how to watch the videos and download any attached files or documents for this lesson…click here.

Lesson 309 – Balance the Workload


In the Level 2 – Lean Practitioner training course you learned how Step 7 – Balance the Workload is focused on leveling the workload across each operation involved in the process.

You learned that the most effective means of moving an item through a system is to create continuous flow! If, the workload is unbalanced between operations, then the flow will be sporadic with constant stopping and starting throughout the system. This creates waste and generates unnecessary downtime.

In the Level 3 – Lean Expert training course, you will learn about the detailed application and integration of Step 7- Balance the Workload as part of a continuous process improvement methodology.

Transformation requires a plan and an infrastructure that is focused on waste reduction to improve value for the customer. It also requires a strong management team that is willing to support the process because the right kind of change does not happen by chance!

In Step 6 – Implement a Pull System, you learned to control the scheduling of inventory replenishment through the use of visual controls. In this next step, you will learn how to improve flow by balancing two critical factors, which are 1) work content and 2) work scheduling.

Lesson 309-1: Introduction to Step 7 Balance the Workload (3:03) In this introduction video, Chris Turner gives an overview of the Level 3 – Lean Expert Step 7 Balance the Workload training materials, and he explains why they are integral part of the 10 Step training and implementation process – 

Lesson 309-2: Step 7 Balance the Workload Part 1 (18:45) – 
To download the documents for Step 7 Part 1…click here

Lesson 309-3: Step 7 Balance the Workload Part 2 (28:17) – 
To download the documents for Step 7 Part 2…click here

Lesson 309 – Additional Learning Resources


Throughout the Lean Expert course we try to share relevant information that gives a practical example of the application of the lean tools and techniques presented in the training materials.


Video 1: In this video by the Lean Academy, you can see a live simulation that is demonstrating how to recognize and improve line balancing (2:27) – Click here to view video


Video 2: In this video, you will see a demonstration of how to calculate the desired cycle times to determine the number of workstations to design and balance an assembly line (6:20) – Click here to view video

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