Determining Takt Time in Metal Stamping

[hassancad]

I work in a metal stamping company. We have 12 presses and we make about 58 different parts with these presses.

We can make 25 brackets with one press which we run some of them once a year and some every week.

I do not know how to calculate Takt time? should I do it based on each release, every week, or amount of total PO?
Could someone help me find out how to calculate Takt time in our process?

Thanks

 

[DRAMMAN]

Why do you need to use the concept of Takt time?

 

[hassancad]

My boss asked me to do lean in our process. I have already found and calculated value added and non value added steps. I believe at this phase I have to compare our process cycle times and Takt time, am I right?

 

[DRAMMAN]

OH BOY!...The boss said to do Lean. That sounds like trouble. Lean is about culture transformation. There is alot more to utlizing Takt time methods. Takt time is simply the quantity needed divided by the time ot do it. As an example. If you 60 minutes and need 60 units then your takt time is 1 minute (ie 1 unit per minute). Then you need ot figure out how to hit the Takt time.

 

[hassancad]

I know i am in big s...
I know the definition but my problem is we have different parts and i do not know should i calculate Tekt time for each part or i have to do it for all parts which to me does not make sense?

 

[DRAMMAN]

This is one of th reason's lean is difficult to imlement at job shops. I would recommedn doing some research on how people have utilized Lean Mfg at job shops. There are several books available on this specific topic.

 

[Golfman25]

Takt time won't be helpful in your situation. It is used for level loading an assembly line. Assuming you're running prog dies without secondaries, you want your presses banging out parts. Good luck.

 

[DRAMMAN]

What type of presses do you have? How long are your production runs? Give some more details on your operation. What has been discussed so far are the typical challenges of adopting Takt Times in job shop environments. If the boss really wants to "do Lean" it might be better to start with some traininga nd research on Lean in Job Shop environments. Then start with 5S and waste elimination. Then move on to more advanced topics.

 

[Taliesyn]

The concept of takt time for items - such as yours - is not fixed. For example, in an engine plant, the takt time is based upon the number of vehicles per day/shift that the customer plant builds. This way, you know if your process will hit on time/in full (according to at least one UK diesel engine manufacturer!)BUT the basic idea falls over if you are talking about the same machine producing vastly different parts at different rates.
For your plant, I would use the planned cycle time. In the past (in a similar plant) we could produce one particular part at 320 parts per minute but the same machine would run at 220 parts per minute for a particularly nasty stainless steel spring ............ so the "takt time" was reduced as necessary.
If you use the planned/expected cycle time, you have a target for the planned/expected number of parts per hour - which you can monitor and, if the machine is not producing parts at the required rate, you know that you have work to do.
If you can exceed the planned/expected parts per hour, you can also adjust the "takt time" to fit the new knowledge and, again, use it as a measure of the ongoing stability of that element of the process.

 

[AMIT BALLAL]

Hi!

Basically, Takt time means what time is actually available for producing the part. (Eg.What time is available to reach to Office).

And Cycle time means what time does it generally need to produce.
(Eg. How much time does it generally take to reach to office)

Follow following steps:
1)calculate what is Quantity required to be delivered to customer,
2) Divide it by total available time in minutes (Excluding Break, lunch, possible breakdown hours),
3)Then you'll get available time (i.e. Takt time) for every piece.


Note:
1) As you'll be producing different parts, every part will require different amount of time due to size & criticality, hence combination of this needs to be done with takt time.
2) First calculate Cycle time, then go for Takt time. This will help while reducing cycle time in order to match takt time.