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Takt Time Video

  • This is a short presentation that will show how to calculate takt time, determine the number of people needed to meet takt time, and how to balance the workload.
  • To calculate takt time you need to know how much time you have available for production each day, and what your customer demand is per day.
  • If you have 16 hours of production time available per day and your customer is demanding 1,000 units per day, convert the hours to seconds, because takt time is expressed as seconds per piece
  • Then divide by the demand to get your takt time. In this case the takt time is 57.6 seconds for each unit
  • Now that you know the takt time, or in other words, how often you have to produce one unit, what is the next step?
  • First of all you need to know how many people will be required to meet that takt time.
  • To find out how many people you need you must know how much work content there is in each unit.
  • The work content is the total time it takes to build one unit. If one unit takes 9 minutes and 18 seconds for example, convert that to seconds, then divide that by your takt time to find out you need 9.69 people. Round that up to 10 people needed for production to meet takt time.
  • You can begin to balance the workload now that you know what your takt time is, how much work content there is, and how many people you need to meet takt time.
  • To balance the workload it is important to know how many steps there are in the work content and how long each step takes.
  • As you can see, there are seven steps to assembling this one unit and the graph also shows how long each step takes in seconds.
  • For this example you have 10 operators, and each operator has just under 60 seconds of available time per unit to contribute.
  • You begin by assigning operators to work steps, and in some cases it will take more than one operator per work step as you see here.
  • You will see that some operators will have available time on their hands as shown, and some operators are going to need some help.
  • To help balance the workload you have the operators with available time help those that need it as shown.
  • There are endless possibilities for laying out the assembly flow and I would classify them as good, better and best. The best layout is going to be the one that has the least wasted motion.
  • Layout your assembly flow properly, because not meeting takt time can have severe consequences.

If you need help with your assembly flow, or with meeting takt time, give us a call today. We're the guys who make this process simple!


About the author:

Jeff Hofstetter

Jeff Hofstetter Jeff is the President of Xtreme Lean Consulting with over 24 years of experience in Lean and Six Sigma Consulting. Jeff is a results-driven, decisive leader with a proven track record of initiating time and cost-saving operational improvements while leading diverse teams to strong, sustainable performance gains. Skilled mentor and coach with a hands-on, positive approach to resource management, leadership development, and training.

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