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Takt Time Calculations

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Yuvraj Hedaoo
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123 views5 pages

Takt Time Calculations

Uploaded by

Yuvraj Hedaoo
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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29/09/2016

TaktTime

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TaktTime
TaktTimeistherateatwhichproductsorservicesshouldbeproducedtomeettherateof
customerdemand.ItisderivedfromtheGermanword,Taktzeit,whichisoftenreferredtoas
theheartbeatordrumbeatofproductioninLeanManufacturing.
Thevalue,inconjunctionwiththecurrentloading(production)rates,isusedtoanalyze
processloads,bottlenecks,andexcesscapacity.Thestudywillindicatewhichoperations
areaheadofthedemandrateandwhicharenot,bothindicatingopportunitiesfor
improvement.Thisisstrictlyaformulaandcalculation.Useittocomparethemeasured
"loading"toquantifywhetheranoperationmeets,exceeds,andbyhowmuch.

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Theunitoftimeinthenumerator&denominatormustbethesame.
Thenumerator,AvailableWorkTime,isoftenexpressedasMinutes/Shift,Seconds/Day,
Minutes/Dayandsoon.
Thedenominator,CustomerDemandRate,isoftenexpressedasParts/Min,Units/Shift,
Pieces/Day,andsoon.
EXAMPLE:
Belowisanexamplecalculation.ItislabeledPROCESS1becauseiftheamountofwork
timeavailableORthedemandonthatparticularmachineorgroupofmachinesvariesfrom
oneprocesstoanothertheneachprocesswillhaveitsowntakttime.

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TaktTimeandLoadingCalculator
ATaktTimecalculator(alongwithothertemplatesandcalculators)withan
exampleisavailablehere.Theformulaswithinthespreadsheetarevisible
tohelpcomprehendtheimpactoftheinputs.

Takttimevaluesarerarelythesameacrosstheentirevaluestreamifthelayoutis
departmentalized.Chancesarethesemachines(processesorservices)sharedemand.
However,inmanyworkcells,allthemachineshavethesamecustomerdemandrateandthe
sameavailableworktimemakingthelinebalancingactivityaneasiertask.
Example:
IfCustomerAorders55,000units/daythatrequireProcess1(fromabove)andtheseunits
alsorequiredownstreamProcess2
AND
CustomerBnowplacesanorderandwants55,000units/daythatrequireProcessAand
NOTProcess2thenthetakttimeforeachprocessisdifferent.
Giventheworkavailableisthesameforeachprocessat22hours/day=1,320minutesper
day=79,200sec/day.
CALCULATION:
Process1:TaktTime=79,200sec/day/110,000units/day=0.72SEC/UNIT
Process2:TaktTime=79,200sec/day/55,000units/day=1.44SEC/PART

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TaktTime
Conclusion
Theloadrate(productionrate)mustbetwiceasfastonProcess1thanProcess2tokeepup
withcustomerdemand.
Thoseoperationsthatareperformingbetterthantakttimealsohaveopportunityfor
improvementoftentheloadfromaprocessthatisbehindcanbeoffloadedandshared.The
amountisdeterminedbythedifferencesinthecurrentloadandtakttimestudiesforeach
process.
Levelingtheworkload,linebalancing,acrosstheprocessesbystudyingthesevaluesisthe
team'swork.
Thestudyisnormallydepictedusingbargraphsandwillnotonlyshowbottlenecksor
excesscapacitybutwillquantifytheamountandshowrelativitybetweenalloperations.

InterprettheChart
Thechartbelowshowstheresultsofanevaluationofthenineprocess(AH)toproducea
particularproduct.Whattakeawaysarethere?

ProcessesB,C,D,Ehaveexcesscapacitysincetheyareoutperformingthecustomer
demandortakttime.Insuchasituation,evaluatethemanpowerforthepossibilityofshifting
ittoaconstraintoperationorreduceovertime.
ProcessesA,F,G,H,andIarenearlyperfectlymatchedandperformingatthetakttime.In
realitythisisverydifficulttoachieveandmaintainloadingattheexactleveloftakttime.For
one,thetakttimeoftenchanges(customerdemandchanges).
ProcessHmaybeaminorconstraint.PerhapsaSMEDeventcoulddeliverenough
improvementtoalleviateanybottleneck.
Inthistypeofsituation,thereshouldnotbeanylatedeliveriestothecustomer.Ofcoursethis
isasnapshotintime.Iftheloadingorthetakttimehavealotofvolatility(orvariation),then
thatisnotgoingtoshowupnecessarilyinthischart.Aswithanytoolthatrepresentsasnap
shotintime,variationcouldresultinmanyproblems.

Bottlenecks
BottleneckoperationsarethoseoperationswheretheLoadCycle>TaktTime.
Itmaycommonlybeknownbytheteammemberswhichoperationshavecapacityandwhich
aretheconstraintsbutitisnotknowntowhatdegreeandamountcomparedtotheother
processes.
Inordertomeetthedeliverydemandsofthecustomereachbottleneckwillneedtoresolved
sotheloadingisfasterthanthetakttime.
Butwheredoyoufocusyoureffortsfirst?
Thestudywillonlyprovidenumbers.Asmallconstraintinoneareaduetohighscrapand
reworkmaybemuchcostlieroverallthanalargertimeconstraintinanotherarea.
Thesenumbersalongwithreasoningoncosts,scrap,andothersubjectivemeasuresarefor
theteamtodetermineprioritizationfortheimprovements.
ThisiswhyaFinanceprofessionalandkeystakeholdersmustcontributetotheteam.Asa
SixSigmaprojectmanageryoucanonlypresentthenumbersbutalsoofferupwhatisNOT
inthenumbersthatcouldshiftpriorities.
Thegoalistogettheentirelinebalancedwhileremovingwaste.Wastereduction(rework,
scrap,overproduction,andother7Wastes)shouldbetargetedaggressivelyandthena
loadingstudyshouldbedonepriortosignificantinvestmentsintolinebalancing.

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Videos&MoreExamples
How to calculate takt time? (+ free excel sheet d...

Process Capacity (Video 17)

ReturntotheIMPROVEphase
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