How do you apply the concept of takt time to synchronize your production rate with customer demand?

1 How to calculate takt time

To calculate takt time, you need to know two things: the available working time and the customer demand. The available working time is the total time that your production process is operating, minus any breaks, maintenance, or downtime. The customer demand is the average number of units that your customers buy or order in a given period, such as a day, a week, or a month. The formula for takt time is: Takt time = Available working time / Customer demand For example, if your production process runs for 8 hours a day, with one hour of breaks and maintenance, and your customer demand is 240 units per day, your takt time is: Takt time = (8 - 1) x 60 / 240 Takt time = 420 / 240 Takt time = 1.75 minutes This means that you need to produce one unit every 1.75 minutes to meet your customer demand.

2 How to use takt time to balance your workstations

Once you have calculated your takt time, you can use it to balance your workstations, or the steps in your production process. This involves ensuring that each step takes the same amount of time as the takt time, or as close as possible. This way, you can avoid bottlenecks, overproduction, idle time, and inventory buildup. To balance your workstations, you need to first break down your production process into discrete steps or tasks and measure the time it takes to complete each one (cycle time). Then compare the cycle time of each step with the takt time. If the cycle time is longer than the takt time, you need to find ways to reduce it such as eliminating waste, simplifying the task, or adding more resources. Conversely, if the cycle time is shorter than the takt time, you need to find ways to use the extra time such as cross-training, quality checks, or preventive maintenance. Lastly, adjust the number and layout of your workstations to match the takt time. This may involve combining, splitting, or rearranging steps or moving equipment and materials closer together in order to create a smooth and continuous flow of work with minimal waste and variation.

3 How to monitor and adjust takt time

Takt time is not a fixed number; it is a dynamic indicator that reflects the current state of your production system and customer demand. Therefore, you need to monitor and adjust your takt time regularly to ensure you are always in sync with your customers. To do this, track your actual production output and compare it to customer demand. If output is higher, recalculate takt time and rebalance workstations. If output is lower, identify and eliminate root causes of deviation and adjust takt time and workstations accordingly. Additionally, track working time and compare it to planned working time. Identify any unplanned downtime, quality issues, or process inefficiencies. Also, anticipate any changes or fluctuations in customer demand; if it increases, increase production rate and reduce takt time; if it decreases, decrease production rate and increase takt time. Finally, communicate and coordinate with suppliers, workers, and customers to adjust takt time and workstations accordingly.

4 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?