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    Module 17. Takt Time

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    taghavi1347
    This document discusses takt time, which is a key concept for understanding and improving processes. It defines takt time as the time required to produce components to meet customer demand. An example is provided to demonstrate how to calculate takt time using available operating time and customer requirements. The relationship between takt time and theoretical minimum staffing is explained. Finally, cycle time bar charts are introduced as a way to visualize production lines and identify opportunities for improvement by comparing operator cycle times to the takt time.

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    Module 17. Takt Time

    Uploaded by

    taghavi1347
    93 views15 pages
    This document discusses takt time, which is a key concept for understanding and improving processes. It defines takt time as the time required to produce components to meet customer demand. An example is provided to demonstrate how to calculate takt time using available operating time and customer requirements. The relationship between takt time and theoretical minimum staffing is explained. Finally, cycle time bar charts are introduced as a way to visualize production lines and identify opportunities for improvement by comparing operator cycle times to the takt time.

    Original Description:

    National Guard Six Sigma Black Belt Training

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    This document discusses takt time, which is a key concept for understanding and improving processes. It defines takt time as the time required to produce components to meet customer demand. An example is provided to demonstrate how to calculate takt time using available operating time and customer requirements. The relationship between takt time and theoretical minimum staffing is explained. Finally, cycle time bar charts are introduced as a way to visualize production lines and identify opportunities for improvement by comparing operator cycle times to the takt time.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    93 views15 pages

    Module 17. Takt Time

    Uploaded by

    taghavi1347
    This document discusses takt time, which is a key concept for understanding and improving processes. It defines takt time as the time required to produce components to meet customer demand. An example is provided to demonstrate how to calculate takt time using available operating time and customer requirements. The relationship between takt time and theoretical minimum staffing is explained. Finally, cycle time bar charts are introduced as a way to visualize production lines and identify opportunities for improvement by comparing operator cycle times to the takt time.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 15

    National Guard

    Black Belt Training


    Module 17

    Takt Time
    UNCLASSIFIED / FOUO

    CPI Roadmap – Measure


    8-STEP PROCESS
    6. See
    1.Validate 2. Identify 3. Set 4. Determine 5. Develop 7. Confirm 8. Standardize
    Counter-
    the Performance Improvement Root Counter- Results Successful
    Measures
    Problem Gaps Targets Cause Measures & Process Processes
    Through

    Define Measure Analyze Improve Control

    TOOLS
    •Process Mapping
    ACTIVITIES
    • Map Current Process / Go & See •Process Cycle Efficiency/TOC
    • Identify Key Input, Process, Output Metrics •Little’s Law
    • Develop Operational Definitions •Operational Definitions
    • Develop Data Collection Plan •Data Collection Plan
    • Validate Measurement System •Statistical Sampling
    • Collect Baseline Data •Measurement System Analysis
    • Identify Performance Gaps •TPM
    • Estimate Financial/Operational Benefits •Generic Pull
    • Determine Process Stability/Capability •Setup Reduction
    • Complete Measure Tollgate •Control Charts
    •Histograms
    •Constraint Identification
    •Process Capability 2

    Note: Activities and tools vary by project. Lists provided here are not necessarily all-inclusive. UNCLASSIFIED / FOUO
    UNCLASSIFIED / FOUO

    Objectives

     Understand the following:


    – Takt Time
    – Theoretical minimum staffing levels
    – Takt Time, Cycle Time Bar Charts
    – How all of these concepts assist in
    understanding and improving a process

    UNCLASSIFIED / FOUO
    UNCLASSIFIED / FOUO

    Definition of Takt Time


     Time required to produce a component or set of
    components to meet customer demand

    Operating Time
    Takt Time =
    Customer Requirements

     Subject to change – depending on demand from


    the customer
     Determines rate of production
     Key to determining resource requirements
    4

    UNCLASSIFIED / FOUO
    UNCLASSIFIED / FOUO

    Takt Time Example – Step 1


    Step 1: Determine available time

     Aircrew Flight Equipment (AFE) has 1 hour a day to test life


    vests
    52 (weeks) * 5 (days/week) * 1 hour = 260 hours

     Convert to minutes
    260 hours * 60 minutes/hour = 15,600 minutes

    Answer: 15,600 minutes is the total available operating time


    per year

    UNCLASSIFIED / FOUO
    UNCLASSIFIED / FOUO

    Takt Time Example – Step 2

     Step 2: Determine Customer Requirement


    – Average daily customer demand
    – Get this anyway you can
    • Advance orders
    • Forecasts
    • Historical data
    • Best guess!
    – For this example, AFE has 3,120 life vests to maintain
    3,120 units per year is the customer requirement

    UNCLASSIFIED / FOUO
    UNCLASSIFIED / FOUO

    Takt Time Example – Step 3

     Divide operating time by demand

    15600 minutes/year divided by 3,120 units/year

     Takt time = 5 minutes (300 seconds)

     This is the time that each process step CANNOT


    exceed in order to meet customer demand using
    single piece flow!

    UNCLASSIFIED / FOUO
    UNCLASSIFIED / FOUO

    Takt Time vs. Cycle Time

     Cycle time is the time for an operator to do a prescribed


    task and return to his or her original stance
     Don’t confuse cycle time and Takt Time!!

    WHAT’S WRONG WITH THIS QUOTE ??


    “Those people have Takt time down to a science! Their Takt time
    is 54 seconds. They make a car in 54 seconds and every step in
    the process takes 54 seconds. And they have a plan to reduce
    their Takt time to 52 seconds through constantly improving every
    job! Amazing!!!”

    UNCLASSIFIED / FOUO
    UNCLASSIFIED / FOUO

    Takt Time & Theoretical Minimum Staffing

    If we:
    • Understand the Total Cycle Time required to
    produce a unit, and we have
    • Calculated the Takt Time of this unit

     We can calculate the theoretical minimum staffing


    required. This is calculated as:

    TOTAL CYCLE TIME


    = MINIMUM STAFF REQUIRED
    TAKT TIME

    UNCLASSIFIED / FOUO
    UNCLASSIFIED / FOUO

    Theoretical Minimum Staffing - Example


    If the Total Cycle Time of all the operators combined =
    720 seconds
    AND
    The Takt Time is 300 seconds

    WHAT IS THE MINIMUM STAFFING REQUIREMENT


    FOR LIFE VESTS IN AFE?

    720 sec/300 sec = 2.4 …so 3 People


    In your experience, what are some of the practical issues
    that make it difficult to hit this minimum staffing??
    10

    UNCLASSIFIED / FOUO
    UNCLASSIFIED / FOUO

    Cycle Time Bar Charts


    Takt Time – Cycle Time Bar Charts enable us to visualize a
    production line with data and determine some of its
    operating characteristics
    Operator Cycle Time in
    Seconds/Part
    Let’s look at a sample chart
    80 70
    Takt Time = 60 Sec
    60
    45
    40
    40 30

    20 15

    0
    Oper.1 Oper.2 Oper.3 Oper.4 Oper.5
    11

    UNCLASSIFIED / FOUO
    UNCLASSIFIED / FOUO

    Cycle Time Bar Chart - After


    Operator Cycle Time in
    Seconds/Part

    80
    Takt Time = 60 Sec
    60 60 60
    60

    40
    20
    20

    0
    Oper.1 Oper.2 Oper.3 Oper.4
    12

    UNCLASSIFIED / FOUO
    UNCLASSIFIED / FOUO

    Cycle Time Bar Chart - Final


    Operator Cycle Time in
    Seconds/Part

    80
    Takt Time = 60 Sec
    60 60 60
    60

    40

    20

    0
    Oper.1 Oper.2 Oper.3

    13

    UNCLASSIFIED / FOUO
    UNCLASSIFIED / FOUO

    Takeaways

     Takt Time is based on customer demand – it is


    the time in which a task must be completed to
    meet the customer requirements
     Cycle time is the time it takes to actually
    complete the task
     Use takt time and cycle time to determine
    theoretical minimum staffing levels
     Visually display staffing levels using Cycle Time
    Bar Charts to help improve the process

    14

    UNCLASSIFIED / FOUO
    UNCLASSIFIED / FOUO

    What other comments or questions


    do you have?

    15

    UNCLASSIFIED / FOUO

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