Takt time is used to synchronize pace of production with the pace of sales. A sort of just-in-time production measure that helps remove and avoid waste.
Takt time = Net Available time / Customer Demand.
- The goal of is to produce to demand
- Can only be changed if the available time or customer demand changes.
- Must be recalculated on a regular basis.
- Should drive staffing decisions and cell layout.
- Should NOT be adjusted to account for system problems.
- Pace the process to a planned cycle time to accommodate system problems.
Calculating Takt Time
Step 1: Calculate the Net Available time
- Includes planned downtime
- Ex. Breaks, lunches, clean-up time, teem meetings, TPM
- Does not include
- Material outages, breakdowns, member lateness, changeovers.
Step 2: Calculate the Customer Demand
810 minutes / 300 pieces = 2.7 minutes per piece.
Customer demand = 30 units / hour.
Process can do the following: 1: 20/hr; 2: 40/hr; 3:12/hr; 16/hr.
Net operating time is 60 mins / hour. The process is irrelevant here. The customer requirements are 30 units per hour. 60 / 30 = 2 mins.
The output of a process has a Takt time of 60 seconds. Station 4 can only produce every 80 seconds. It exceeds the Takt time and is unable to keep pace.
A shop can work 430 mins a day.
The customer needs 300 units per day.
Takt time = 430 / 300 = 1.433 minutes per unit.
A manager wants to set up a Kanban system on an assembly process. The demand for the part produced in the target process is 75/units per hr and MLT of the process is .6 days. The factory operates two 8.5 hour shifts, with 30 minutes of break timer per shift. Assuming the safety stock should be set at 10% and container capacity is held at 10% of daily demand, how many Kanban card sets should be authorized?
Net available time = 8.5 + 8.5 – .5 – .5 = 16 hours per day
Customer demand = 75 units / hour * 24 hours per day = 1800 units per day.
Total demand = customer demand + safety stock + container capacity = 1800 + 0.1*1800 + 0.1*1800 = 2160
Takt time = Net Available time / Customer Demand = 16 / 2160 = 0.0074
Percent loading chart: compares Takt time (rate of customer demand) to cycle time (“touch time” – or process time).
ASQ Black Belt Takt Time Questions
Question: Which of the following is an element of standard work?
(A) Takt time
(B) Product cost
(C) Product value
(D) Maximum inventory