What is Takt time and Takt time calculation



Learn about Takt time and Cycle time in detail with examples. We will also see what approach can be taken for cycle time reduction.

The word takt is a German word for baton, used by an orchestra conductor. This provides a rhythm to the process similar to a heartbeat. This means that the process is flowing at a certain pace or rhythm. It will be explained here with some simple examples, takt time is not only about calculation but we also need to understand the role of takt time in CFM (Continuous Flow Manufacturing) .

In CFM (Continuous Flow Manufacturing) a certain pace is maintained, the line must be engineered to do so. Takt time is term used (first by Toyota) to define a time element that equals the demand rate. In CFM or one piece flow, the time allowed for each activity/line operation is limited. The line is balanced so that each operator can perform their work in the time allowed.

An example of the calculation of takt time is shown below :

The takt time will be 1.43 min per unit or 86 sec per unit. The ideal pace of each operation is set at 86 sec.

For the plant that does not have the luxury of mass production to establish a single takt time, the solution may be to develop multiple takt time, breaking the requirements into smaller components.

The necessary quality, machine, personnel, materials and supplier resources must be coordinated and made available as needed. The layout of the line or cell is a starting point. The line should be examined as necessary to:

1. Improve cycle time

2. Reduce product defects

3. Correct long changeover times

4. Address equipment reliability (or breakdown) issues

Line balancing using Takt time

We will take an example of a line with 5 stations. If the takt time for a station is 60 sec, the first observation is that station 4 exceeds the takt time and will not be able to maintain the pace. An option would be to have some of the time eliminated by moving work to another station.

In the next step we observe that station 1, 2 and 5 do not come up to the takt time. There is slack there which needs to be addressed. Only station 3 has a full 60 sec of work. In Lean manufacturing, we need to review the line for a redesign of the process.

The total work time used in the current scenario is 265 sec. With 5 operators, this will be 53 sec on a balanced line. A deeper look indicates that 4 operators will require 66.25 sec. This is a little more than the desired takt time of 60 sec. Now the most important task will be to look at the value add(Vas) and non value add(NVAs) in the process. A thorough study of the tasks may reveal that a significant portion of time can be eliminated leading to a reduction of 1 operator and possibly a reduction of floor space as well.

Fig – 3 shows various options, option 1 is to balance the line at 53 sec. This will provide 7 sec of slack for each operator as the takt time was 60 sec. Option 2 reduces the number of operators and redistributes the work load. This redesign has an initial takt time of 66.25 sec.

The next step is a kaizen event in which the team can identify NVAs and reduce the work time for each station to 60 sec as shown in option 3.