Q. 148  Use examples from different scenarios along with the Takt time calculator at https://www.benchmarksixsigma.com/calculators/takt-time/ to explain the meaning of Takt time.

 

  

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Before analyzing the Takt Time calculator let us understand first what Takt Time is all about.

 

Takt Time: This is the rate in time per unit at which the process must complete units in order to achieve the customer demandime . It may computes as

take Time = Time available/Number of units to be produced

 

Takt time is basically a time based measure which is sometimes confused with cycle time. Cycle time is total time taken to complete the work. for any work task at a station cycle time must be less than or equal to takt time.

 

Available time does not include luches, breakdown, and planned downtime. So to meet the demand takt time can be reduced if there is any breakdown or downtime.

 

for example in car manufacturing industry , lets assume daily car production target is 500 in  two shifts of 960 minutes. Lets not include of lunch, break so we have 900 minutes to produce 500 cars. 

 

SO takt time is : 900/500 = 1.8 minutes or 108 sec which means in every 108 seconds one car must be out form shop floor. 

lets assume demand is increased to 800 cars in a day in festive seasons then takt time will be reduced , revised takt time is now = 900/800 = 1.12 minutes or almost 68 sec.

 

we have seen that takt time has been reduced as demand increased , so in every 68 sec car must be out form shop floor and any activity at a particular station which is defined must be completed before takt time. or in other words cycle time at every station should be equal or less than takt time to meet the requirement.

it may be possible that we have to deploy extra manpower, processes to reduce the cycle time at station to meet our takt time.

 

Similarly example can be seen in any industry like, foods, beverages , air conditioning, their demands fluctuates throughout the year so on forecasting bases takt itme can be increased or decreased and planning of manpower and other item can be done in advance which will be helpful in cost saving for the organization also. 

 

For example demand is not there and organization has maintained its takt time of 68 sec to deliver cars by investing on  extra machines, overtime, extra manpower which is a waste for the organization as it leads to high inventory of finished good for which organization needs more space which is also a wasteful activity and loss to the organization.

 

Lets understand with calculator:

1. Total customer: this is the daily customer demand which changes from industry to industry like automobile, four wheeler, two wheeler, heavy commercial vehicle, daily consumer goods industry, . this is a foretasted demand which is derived from its yearly plan which is based on its previous history and its upcoming plan to the market as per the market. it may vary throughout the year eg in case of icecream which is more consumed in summer time  than the winter time. Same is with automobile industry where demand is more in case of festive seasons. 

 

For example we have a demand of 1000 bikes in a day.

 

2. Production Time : this is the time available for production for example if any industry operates in 2 shifts then it will be 2*8*60 = 960 minutes and in case of 3 shifts then it will be 3*8*60 = 1440 minutes. 

 

For above example lets suppose we have two shifts of total time is 960 minutes.

 

3. Break time: this time is break time for lunch, tea in shifts and to calculate Takt Time, this time excluded from production time so we assume our total break time for lunch &  in two shift is 90 minutes then we have available time is only 960-90= 870 minutes.

 

means we have only 870 minutes to produce 1000 bikes as per our example so our takt time will be : 870/1000 = 0.87 minutes or 52 sec. as now we have available time is 870 minutes. 

 

4.  Down time:  this may be planned or unplanned and to calculate takt time , down time must be excluded as during this time is not used for production. So if we exclude downtime then our takt time will be reduced. 

Suppose our total downtime is 70 minutes so now total available time is 870 - 70 = 800 minutes to produce 1000 bikes.

 

so revised takt time is : 800/100 = 0.8 minutes or 48 sec which is less than before , so to meet this target we have to deploy extra manpower of increase speed of line and reduce cycle time at every station to finish the defined work to match the demand. 

 

takt time changes with demand and total time availability. it is a very simple concept which gives us production stability by limiting overproduction and stabilizes the system. As we have seen in our example also it prevent us to build up inventory which is an unnecessary waste for any organization. 

Takt Time

Takt time is the maximum amount of time required to produce unit’s specific to the satisfaction of customer demand. “Takt” means pulse. Takt creates the rhythm to carry out the business in a continuous flow and proper utilization of resources.

Before implementing Takt time in operational projects, we should make sure the overall capacity in a business in well planned way and utilization of capacities like man and machine and till is maintaining the customer demand.

Formula:

Takt time = Net time Available for production/ Customer’s Demand

Net Production Time= Total production time - break timings- Shift handover- System downtimes- Maintenance activities time

For example:

Total Time = 8 hours= 8*60= 480 mins

Breaks: 60 mins

Time available = 420 mins

Customer’s demand in 8 hours: 100 transactions

Takt time = 420/100= 4.2 minutes= 252 secs

 

Inference: The customer will need only one transaction in 252 secs to be completed by one user.

                     That’s why before calculating takt time in the processes it is important that the processes are dependable and deliver good quality and has good machine capabilities.

TAKT Time helps is set the rate of production to continue meeting the customer's demand in a timely fashion. Both the answers have correctly mentioned what it means when the production rate is higher or lower than required. The chosen best answer is that Vastupal as he has provided multiple examples.