Introduction to Takt time - January 2017

1Marek.Piatkowski@Rogers.com
Takt Time
Introduction
Thinkingwin, Win, WIN
Takt Time – Pace of Production
Definitions
Marek Piatkowski – January 2017

Takt Time
Introduction
Introduction - Marek Piatkowski
 Professional Background
 Toyota Motor Manufacturing Canada (TMMC) - Cambridge, Ontario from
1987-1994
 TPS/Lean Transformation Consulting - since 1994
 Professional Affiliations
 TWI Network – John Shook, Founder
 Lean Enterprise Institute (LEI) – Jim Womack
 Lean Enterprise Academy (LEA) – Daniel Jones
 CCM/CAINTRA – Monterrey, Mexico
 SME, AME, ASQ, CME
 Lean Manufacturing Solutions - Toronto, Canada
http://twi-network.com

Takt Time
Introduction

Takt Time
Introduction
What is Takt Time?
 Takt Time is a maximum amount of time in which a product needs to be produced
in order to satisfy Customer demand
 Takt Time creates a pulse or a rhythm across all manufacturing processes in a
business and synchronizes issues among processes to ensure continuous flow of
production and utilization of capacities.
 It defines a maximum working time per single part or an assembly for each
Operator to finish their cycle
 It defines a time for each Operator to complete a task
 In practice, all operations produce with a slightly higher pace than what the Takt
Time calculation says. If not, they would not have any opportunity to be able to
fend for disturbances
 Takt Time should therefore not be seen as a tool, but rather a vision. If your
production pace were exactly the same as the mean customer demand, it would
require perfectly stable processes and completely balanced flows. A long term goal
in Lean Manufacturing

Takt Time
Introduction
 Scheduled Production Time - is the total available production time per day (in
seconds). It takes into consideration (subtract) time scheduled for meetings,
maintenance, breaks and lunches.
 Total Customer Requirements - Quantity of parts required from the process per day
Takt Time – is a rate (in seconds) at which you should
produce one part or one product to meet Customer
requirements based on the rate of sales.
Takt Time =
Scheduled Production Time (in seconds)
Total Customer Requirements

Takt Time
Introduction
Why focus on Takt Time?
 The amount of time that material wastes (spends) in an organization is strongly tied
to the amount of controllable cost incurred and the cash flow of the operation.
 Improved material flow - material requires floor space, tracking systems, processing
and handling, most of which add little value while increasing the cost of the
product.
 Once the Takt Time has been established, the amount of individual work is
determined so it can be done within the specified Takt Time
 Creates a pace of production – Rhythm
 Producing to Takt Time sounds simple, but being able to operate to Takt Time is a
result of concentrated efforts to:
 Provide fast response (within Takt Time) to problems
 Eliminate causes of unplanned downtime
 Reduce changeover times

Takt Time
Introduction
Before calculating Takt Time
 Clearly identify a single part or a final product or a product family manufactured in
the selected Work Cell
 Identify the number of parts and components going into the final product that is
manufactured within the boundaries of the Work Cell
 Identify all major manufacturing steps within the Cell
 Use well documented history of shipments to the Customer when calculating
Customer requirements

Takt Time
Introduction
Takt Time Calculations - Example
Scheduled Production Time
 Production Time (work hours) = three 8 hour shifts per day
 Each shift gets:
 30 minutes for lunch
 two 10 minutes breaks
 10 minutes “end-of-the-shift” clean-up
 Each shift = (8 hrs x 60 Min)-30-20-10 = 480 - 60 = 420 min/shift.
 Total Scheduled Run Time = 3 shifts x 420 min = 1260 min => 75,600 seconds

Takt Time
Introduction
Weekly Customer Requirements
 6,750 parts per week
 How many days per week do you operate?
 5 day schedule = 1,350 parts per day 6,750 / 5 = 1,350
 6 day schedule = 1,125 parts per day 6,750 / 6 = 1,125
 7 day schedule = 965 parts per day 6,750 / 7 = 965

Takt Time
Introduction
 Scheduled Run Time = 75,600 sec.
 Weekly Customer Requirements = 6,750 parts
 5 day schedule - 1,350 parts/day
 6 day schedule - 1,125 parts/day
 Takt Time
 5 day schedule = 75,600/1,350 = 56 sec.
 6 day schedule = 75,600/1,125 = ~ 68 sec.

Takt Time
Introduction
Recommended Takt Time – 30 ?, 60 ?, 90 ? Seconds
 The most commonly Takt Time used in the automotive Industry is about 60 seconds
 It is proven (demonstrated) that 60 seconds Takt Time is:
 Easier to balance production flow
 Easier to train – number of work elements to remember
 Easier to rotate and cross-train
 Simplifies manpower planning
 Elements move easier from station to station
 Ease of auditing to see if operator following standardized work
 This does not mean that there is something wrong with Takt Times less or more
than 60 seconds

Takt Time
Introduction
Pacing the Line - Operating to a Steady Takt Time
 Operators can get into a rhythm
 Creates predictable flow - repetitive manufacturing
 Production planning becomes easier
 Operating efficiency goes up
 Makes problems obvious

Takt Time
Introduction
Manpower Calculations
Operators
A B C D
Customer Demand Rate (60 sec.)
Takt Time = 60 seconds
5 Operators
EA B C D
Operators
Customer Demand Rate (60 sec.)
4 Operators
Takt Time = 60 seconds

Takt Time
Introduction
Manpower Utilization
5
10
15
20
25
30
D2 - 26
Takt Time = 27 sec
D2 - 10 D2 - 12 D2 - 14 D2 - 16 D2 - 18 PP - 01 D2 - 01PP - 03
X

Takt Time
Introduction
Changing the World. One Transformation at a time
This presentation is an intellectual property of W3 Group Canada Inc.
No parts of this document can be copied or reproduced
without written permission from:
Marek Piatkowski
W3 Group Canada Inc.
iPhone: 416-235-2631
Cell: 248-207-0416
Marek.Piatkowski@rogers.com
http://twi-network.com

Takt Time
Introduction
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Introduction to Takt time - January 2017

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Introduction to Takt time - January 2017