National GuardBlack Belt Training

Module 17

Takt Time

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CPI Roadmap – Measure

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

TOOLS

•Process Mapping

•Process Cycle Efficiency/TOC

•Little’s Law

•Operational Definitions

•Data Collection Plan

•Statistical Sampling

•Measurement System Analysis

•TPM

•Generic Pull

•Setup Reduction

•Control Charts

•Histograms

•Constraint Identification

•Process Capability

ACTIVITIES• Map Current Process / Go & See

• Identify Key Input, Process, Output Metrics

• Develop Operational Definitions

• Develop Data Collection Plan

• Validate Measurement System

• Collect Baseline Data

• Identify Performance Gaps

• Estimate Financial/Operational Benefits

• Determine Process Stability/Capability

• Complete Measure Tollgate

1.Validate the

Problem

4. Determine Root

Cause

3. Set Improvement

Targets

5. Develop Counter-

Measures

6. See Counter-MeasuresThrough

2. IdentifyPerformance

Gaps

7. Confirm Results

& Process

8. StandardizeSuccessfulProcesses

Define Measure Analyze ControlImprove

8-STEP PROCESS

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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

Objectives

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

Subject to change – depending on demand from the customer

Determines rate of production

Key to determining resource requirements

Takt Time =Operating Time

Customer Requirements

Definition of Takt Time

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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

Takt Time Example – Step 1

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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

Takt Time Example – Step 2

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Divide operating time by demand

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

Takt time =

This is the time that each process step CANNOT

exceed in order to meet customer demand using

single piece flow!

5 minutes (300 seconds)

Takt Time Example – Step 3

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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!!!”

Takt Time vs. Cycle Time

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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

TAKT TIME= MINIMUM STAFF REQUIRED

Takt Time & Theoretical Minimum Staffing

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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?

In your experience, what are some of the practical issues

that make it difficult to hit this minimum staffing??

720 sec/300 sec = 2.4 …so 3 People

Theoretical Minimum Staffing - Example

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70

40

15

45

30

0

20

40

60

80

Oper.1 Oper.2 Oper.3 Oper.4 Oper.5

Operator Cycle Time in

Seconds/Part

Takt Time = 60 Sec

Takt Time – Cycle Time Bar Charts enable us to visualize a

production line with data and determine some of its

operating characteristics

Let’s look at a sample chart

Cycle Time Bar Charts

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60 60 60

20

0

20

40

60

80

Oper.1 Oper.2 Oper.3 Oper.4

Operator Cycle Time in

Seconds/Part

Takt Time = 60 Sec

Cycle Time Bar Chart - After

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60 60 60

0

20

40

60

80

Oper.1 Oper.2 Oper.3

Operator Cycle Time in

Seconds/Part

Takt Time = 60 Sec

Cycle Time Bar Chart - Final

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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

Takeaways

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What other comments or questions

do you have?