Published: 07 April 2021

Is Takt Time Important ?

Takt Time – What is it ?

Definition:  Takt is the maximum amount of time required to produce the product to satisfy your customer demand, or in other words, it is the net time available to work per the unit of customer demand.

There is often confusion with Takt time and Cycle time – so we shall look at this first:

Takt Time is a customer demand calculation that tells you how often a part should be completed in order to meet demand.

Cycle Time is how often a part is completed by a particular process.

 

Why operate to Takt Time ? 

If you expect people to do something other than produce all day, you have to give them time to do it.

By operating to Takt it allows the leadership to see disruptions and act on them – taking on a Problem-solving role to support the production process.  

 

As leaders, they will need a way to determine the minimum resource necessary to get the job done 'Just in Time' (JIT), and a way to continuously compare what is actually happening vs. what should be happening (Short Interval Control), and then a process to immediately act on any difference. 

Takt time is the method for doing this. It is so effective, in fact, that it is largely considered a necessary fundamental, yet it rarely gets discussed enough. 

 

What are the benefits of operating to Takt time?

 

- Guarantee of Service Level 

- Tighter control of Conversion Cost

- Capacity calculations can be accurately made 

- Process capability can be determined

- Required pace of machine and other production equipment can be determined to ensure efficiency

- Minimum batch sizes can be calculated in relation to changeover

- Efficient and accurate labour planning 

- Opportunities for improvement activity can be identified because it will make problems visible (8 Wastes)

- It allows real time targets for production to be set

- Reduces unnecessary waste in Overproduction (the worst form of waste)

- Earlier detection to signal when something is going wrong within a process  

 

How do we calculate Takt Time?

The classic calculation for takt time is:

 

     Available Minutes for Production

________________________________________     = Takt Time

       Required Units of Production 

 

What constitutes available time? 

The total shift time(s) and subtract breaks and planned downtime.

As an example: 

Working Hours 08:00 - 16:30 8.5 Hours (or) 510 Minutes
No. of Shifts 1  
No. of Days 5  
Breaks Lunch 30 Minutes
  Startup 10 Minutes
  Other Breaks 2 x 10 Minutes = 20 Minutes
  Clean Up 15 Minutes

 

Breaks: Total of 75 Minutes

This time is not production time, so it is subtracted from the available minutes:

510 Minutes – 75 Minutes = 435 Minutes or 26,100 seconds

If you convert Raw Materials into a saleable item – then you need to operate to Takt Time in order to meet your Customer Demand within your identified Cost parameters, regardless of your demand rate. 

Available Time Daily Demand Takt

435 Minutes (or)

26,100 Seconds

25 Units 17.4 Minutes (or) 1044 Seconds 
  5,000 Units 0.09 Minutes (or) 5.2 Seconds

 

It really doesn't matter if your manufacturing operation produces slow moving or fast moving products, 'Takt' should be the heartbeat of your conversion processes.

If your business is unable to consistently produce to Takt Time and actions to satisfy customer requirements are impacting on conversion costs as a result, get in touch to see how we can help. 

Published: 07 April 2021