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Takt Time Calculation

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  • #41492

    thevillageidiot
    Member

    I have a line that is comprised of 10 workstations.  The line produces to order and the order pattern is fairly consistant M-F, with an app. daily demand of 10000 units on Monday and progressing up to app. 50000 units on Friday.
    How do I calculate an accurate takt time when the daily demand is fixed in quantity but variable on day of the week and the product is highly variable in form?  Order lead time is 24 hr, and averaging out demand appears to jeopardize OTD and OTS.  Suggestions?  THANKS !!

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    #130154

    ramblinwreck13
    Participant

    TAKT time calculations ask for demand at peak, so from the limited information I have to assume your demand is for 10000 pieces on Monday, 20000 pieces on Tuesday, 30000 pieces on Wednesday, 40000 pieces on Thursday and 50000 pieces on Friday.
    Short of getting your customers to average their demand, or giving them an incentive for smoothing requirements to you, you must calculate TAKT based on 10 people on 1 line making 50000 pieces, @ 85% efficentcy on 1 shift for an availble production time of 382.5 minutes or 22950 seconds making your TAKT time .459 seconds.
    Not very realistic, but I suspect you knew that.
    When you run 40000 on Thursdays, you’ll only need to run the line with 8 people, all switching off in perfect unision to do the job before or after their normal work station to balence the flow, like wise on Wednesday it is run with 6 people, Tuesdays with 4 and Monday 2 people get to bounce all over the line with only 10000 to run.
     
    Hope this helps

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    #130155

    thevillageidiot
    Member

    That was completely helpful!  And despite the fact that we are sworn enemies (UGA undergrad), I dare to ask you one more question…(and here I thought all that “your gonna work for us someday” stuff was hyperbole..)
    Does you answer change if the 10 workstations are decoupled and independent?  Thanks my friend.

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    #130158

    SixSigmaTools
    Member

    Takt Time does not care whether your stations are independant, coupled, etc…
    Takt time is calculated as (Available time / Demand)
    You are required to determine how to meet your takt time whether it is more stations, more employees, more automation, overtime, etc…
    Per the example by ramblinwreck, your output has to meet the takt time or you will not be able to support customer demand.

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    #130186

    TransactionalBB
    Member

    Doesn’t the calculation of number of people require cycle time? I thought that it was number of people= cycle time/takt time
     

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    #130200

    ramblinwreck
    Participant

    I root for the DAWGS 48 weeks of the year, but TAKT time has nothing to do with weather the stations are coupled or independent. It has only to do with Availbile time and demand. If you had two line set up TAKT time would double as staffing it would provide more availbile production time, likewise if you ran the line 3 shifts instead of 1 you TAKT time would triple due to more availible production time.
     
    Hope this helps and we’ll see see who wins this weekend.
    ramblinwreck

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    #130201

    ramblinwreck
    Participant

    The number of people only gives you more opportunites to spread the work over a larger clock time for more availile minutes/seconds.
    For example, having 10 stations in this senerio might imply you want 10 people, but if the demand is low on a particular day, you might want each person to work two stations to have the flexible staff respond to the flexible demand, while always leaving your work content (or TAKT) time constant. 
    TAKT is always calculated based on Availible Seconds/Peak Demand
    If you have more people and work them more shifts, or create a second or third line, to expand availible seconds then you have an impact on your TAKT rate. Take the extreme senerio of  having 5000 people to work 10 stations  on 1 shift ; this will not improve your availible time, your output or decrease your TAKT time.
    Ramblinwreck

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    #130202

    thevillageidiot
    Member

    Great…. thanks! 

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    #130203

    thevillageidiot
    Member

    Right…thank you.

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    #130204

    Ron
    Member

    The availalbe time does not change based on headcount!   Available time is the actual time less planned breaks meetings, lunch etc,. that the line is shceduled to work. Overtime, flex work force  etc. is a mechanism to utilize to meet the TAKT time is the number don’t work
     
    Takt time is availalbe time / demand or ADD (Average Daily Demand)
    To estimate the number of people needed to meet takt time you have to divide the cycle time by the takt time.
    I.e. you have a takt time of 5 minutes you have a cycle time of ten minutes. to meet the Takt time you need to either reduce cycle time to 2.5 minutes or add an additional head.

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    #130414

    thevillageidiot
    Member

    Gents,
    Couple things…as to determining headcount, my impression is that calculation is determined by taking the operator’s cycle time and divide that by takt, not simply the cycle time, which would generally take into account machining and all value-adding / non-value adding elements of production.  Determine the  work content required to produce a unit of product, sum their collective time, and divide that number by takt, and it gets you pretty close to proper staffing levels…just my opinion.
    Still hazy on takt time when considering multiple redundant work stations and flucuating demand:  If demand is stable but variant over the course of the weekdays (M-F 10000 – 50000 respectively), do you alter the demand and recalculate takt?  If not, how do you set takt for F and then for M?  Thanks for the help…regret the density of my grey matter.

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    #130570

    Flowguy
    Participant

    Given the conditions you’ve stated, as your volume changes you should alter Takt, and staff your line appropriately. 
    Here’s the way I see it – (resources are both operations and people, in this case)  I’m assuming a one shift operation with daily available time as 408 minutes (85% of 8 hours) and a product cycle time of 10 seconds.  On Monday, you’ll have 16 workstations sitting idle, and Friday you’ll be fully staffed with 20 stations running.

    10000
    20000
    30000
    40000
    50000
    Daily Volume

    2.448
    1.224
    0.816
    0.612
    0.4896
    Takt (sec)

    10
    10
    10
    10
    10
    Cycle time (sec)

    5
    9
    13
    17
    21
    # of resources required
    Hope this is helpful
    Flowguy

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    #130585

    Da Agent
    Participant

    My 2 cents,
    We have always distinguished between what is “peak” demand here at our facility. So in essence we would show a graph that would show takt time for low and high peak and the number of head count that it would require to hit rate.
    Question: Do you guys distinguish between “cycle time” and “drop rate”???

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    #168136

    Madhusudhan
    Participant

    sir.. please send calculation of takt time

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    #168945

    ashutosh paty
    Participant

    plz send me detail about takt time calculation for weld shop assy line
     
     
    thanks and regards
    Ashutosh paty
    9899766255

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