The Elsmar Cove Business Systems and Standards Discussion Forums Takt Time & Cycle Time Calculations
 Forum User Name Keep Me Logged In Password
 Register Photo Albums Blogs FAQ Registered Visitors Social Groups Calendar Search Today's Posts Mark Forums Read

 Elsmar Cove Forum Visitor Notice(s)

# Takt Time & Cycle Time Calculations

 Elsmar XML RSS Feed Monitor the Elsmar Forum Sponsor Links Courtesy Quick Links Links Elsmar Cove visitors will find useful in the quest for knowledge and support: International Standards Bodies - World Wide Standards Bodies International Organization for Standardization - ISO Standards and Information Quality Digest

Post Number #1
6th February 2011, 12:28 PM
 paxbritannia Total Posts: 1
Takt Time & Cycle Time Calculations

Hello. My name is Daniel from the UK. I am unemployed and decided to do a lean course to improve my chances. I've come across 2 questions that I am not sure how to start making calculations. I'd be grateful if someone can show me the calculation process. The questions are:

1. What should you do if the takt time is 6.0 mins/part and the cycle time is 5.0 mins/part?

2. If 4 operators have cycle times of 17, 16, 15, and 18 minutes with a known takt time of 15 minutes, what is the output of the line?

Thank you and God Bless.

Daniel

Post Number #2
6th February 2011, 12:33 PM
 Stijloor Total Posts: 15,251
Re: Takt Time & Cycle Time Calculations

Welcome to The Cove Forums Daniel!!

Very good questions! Glad you found us.

It is weekend + Super Bowl Sunday, but responses will come.

Stijloor, Forum Moderator.
Post Number #3
6th February 2011, 01:44 PM
 somashekar Total Posts: 5,298
Re: Takt Time & Cycle Time Calculations

Quote:
 In Reply to Parent Post by paxbritannia Hello. My name is Daniel from the UK. I am unemployed and decided to do a lean course to improve my chances. I've come across 2 questions that I am not sure how to start making calculations. I'd be grateful if someone can show me the calculation process. The questions are: 1. What should you do if the takt time is 6.0 mins/part and the cycle time is 5.0 mins/part? 2. If 4 operators have cycle times of 17, 16, 15, and 18 minutes with a known takt time of 15 minutes, what is the output of the line? Thank you and God Bless. Daniel
Takt time comes from a german word which translates to cycle time. Takt time concept aims to match the pace of production with customer's demand.
Takt time can be determined with the formula:
T=Ta/Td
Where
T = Takt time, e.g. [minutes of work / unit produced]
Ta = Net time available to work, e.g. [minutes of work / day]
Td = Time demand (customer demand), e.g. [units required / day]
(courtesy wikipedia)
So
Be happy that the cycle time can meet the demand and have some surplus stock.
If the 4 operators are working in a line one feeding the other, then the cycle time is 18, (the weakest link) and requires a line balancing to improve so as to meet the demand of takt time 15.
 Thanks to somashekar for your informative Post and/or Attachment!
Post Number #4
7th February 2011, 03:07 AM
 harry Total Posts: 6,290
Re: Takt Time & Cycle Time Calculations

Takt time

Cycle time
Post Number #5
7th February 2011, 09:29 AM
Re: Takt Time & Cycle Time Calculations

The posts so far have provided correct math, so:

1. Your process (cycle time = 5 min.) can not only keep up with current customer demand (takt = 6 min.), but will begin to build up inventory - either somewhere mid-process as WIP (work in proces) or at the end as finished goods. Either way, in lean terms, that's waste, as you will be making more than demand called for. From an accounting perspective, it's costing you more to sit there too!

There are follow on exercises and tools which would allow you to arrive at a more optimal match between cycle and takt. This involves load balancing and perhaps reconfiguring your staffing, but those would be "other" questions for the classes you're taking.

2. In this case the math works nicely (that means is easy for me!) For your overall process, the total cycle time, or completion time, is determined by the slowest step. So in this case, it's 18 minutes. Take that against a takt time of 15 minutes, and you find you cannot keep up with demand. At this point, you would need to conduct a value add/non-vlaue add analysis and then probably a line (load) balancing exercise to improve your cycle times so you can meet takt. Given that none of the 4 operators has a cycle time less than takt, probably not an easy puzzle.

Hope this helps.

Cheers!
Post Number #6
22nd July 2011, 03:12 AM
 megahertz Total Posts: 14
Re: Takt Time & Cycle Time Calculations

The slowest process will determine the line cycle time or in engineering term called the "bottle-neck" process. Line balancing would be the best method in this issue. Anyway, as mentioned by AdamP, considering that none of the process are below takt time, it would be a hard task to re-balance.
Post Number #7
30th September 2011, 03:57 PM
 wmarhel Total Posts: 642
Re: Takt Time & Cycle Time Calculations

Quote:
 In Reply to Parent Post by paxbritannia [/B] 1. What should you do if the takt time is 6.0 mins/part and the cycle time is 5.0 mins/part?
First, thank the heavens since the issue is usually a longer cycle time than takt.

You could look at using the additional or free minute of the operator/s to perform some additional value-added activities such as preventative maintenance, problem solving and possibly even fulfilling kanban/s for other areas of the plant.

Another alternative could be to change the process to remove one person with a cycle time that is nearer to takt.

Quote:
 In Reply to Parent Post by paxbritannia [/B] 2. If 4 operators have cycle times of 17, 16, 15, and 18 minutes with a known takt time of 15 minutes, what is the output of the line?
I'm going to disagree with somashekar's post slightly, although not because he's wrong, since on the surface a line only produces at the slowest rate. Based on the times you provided though, the slowest cycle time (18 minutes) at a station would yield 3.33 units per hour. If you take the average of those stations, which equals 16.5 minutes, you could actually get 3.6 units per hour. Assuming of course that the work could be distributed evenly across all operators.

A simple calculation to determine manning is to divide the cycle time of a process by the desired takt. This will yield the manning that should be necessary to meet takt. The particular process might requires some additional effort on processes, standardized work, etc; but that is one of the many reasons for kaizen events.

Regards,

Wayne

 The Elsmar Cove Business Systems and Standards Discussion Forums Takt Time & Cycle Time Calculations

 Bookmarks

 Visitors Currently Viewing this Thread: 1 (0 Registered Visitors (Members) and 1 Unregistered Guest Visitors)

 Forum Posting Settings You may not post new threads You may not post replies You may not post attachments You may not edit your posts BB code is On Emoticons are On [IMG] code is On HTML code is Off Forum Rules

 Similar Discussion Threads Discussion Thread Title Thread Starter Forum Replies Last Post or Poll Vote zaffresky Lean in Manufacturing and Service Industries 10 4th January 2017 03:09 PM leanpractice Lean in Manufacturing and Service Industries 3 11th March 2015 06:05 AM qianzhongmin Lean in Manufacturing and Service Industries 4 20th November 2013 08:43 PM jkittle Lean in Manufacturing and Service Industries 3 10th October 2012 12:58 PM tomccchang Lean in Manufacturing and Service Industries 29 28th November 2011 12:28 PM

The time now is 12:09 AM. All times are GMT -4.