What is Takt Time?
In Lean Manufacturing takt time is the rate at which a finished product needs to be completed in order to meet customer demand. If company has a takt time of five minutes, that means every five minutes a complete product/part, assembly or machine is produced off line because on average a customer is buying a finished product every five minutes. The sell rate- every hour, every days or week is takt time. Takt time is also known as "beat time", "rate time" or "heartbeat".
Takt Time CalculationIn order to use the Takt Time Calculator, you will need two numbers. The first number that is required is D, or the average customer demand for that item per day. The second number is W, or the total available production time in seconds per day. To find "T", you would divide W by D. This will give you the Takt time.
T = W / D in seconds = Takt time.
There are some rules that need to be followed for this calculation. You need to define the day in the light of production, as opposed to demand or the actual consumption. If your processing is only performed 5 days a week, then your daily demand will only be 1/5 of the week. While customers are "consuming" the item 7 days a week, it is only being made 5 days out of the week.There may be a situation where you produce the item more frequently than the customer uses it. Even in this case, the rule still applies. The customer may only use your product 4 days a week, but if you are manufacturing the product 7 days a week, your daily demand will still be 1/7th of the weekly demand.
An Example of the Takt Time Calculator
An example of the rule is given for when production and manufacturing runs in shifts
If you are running your factory for 2 shifts for 5 days every week, and a single shift on one day each weekend, you will run a simple calculation of (2 x 5) for the first five days, and then a 2nd calculation of 1/5 for the weekend day.
Add the two numbers together, and you have 2.2 shifts per days through your "week".
You will calculate your available working time as the number of shifts per day (2.2 in the previous case) times the number of seconds per shift.
Subtract any time that is not being used for production, such as rest breaks, meals, or meetings, set-up, maintenance time, and any unscheduled down time.
The result will be your number of seconds that is required to run all of your production areas.
Let's say that your plant runs for 18 hours per day Monday - Friday and 9 hours on Saturday.
You have 2 hours of downtime for breaks, meetings, lunches, or other downtime Monday - Friday and 1 hour of downtime on Saturday.
This gives you 2.2 shifts per day. Multiply that by the number of seconds per shift. In this case, each shift is 9 hours, so 32,400 seconds x 2.2 is 71,280 seconds.
Subtract the number of seconds not used in production, which in this case is 1 hour per shift, or 3,600 seconds. The result is 67,680 seconds.
If customer demand is for 100,000 items, you would divide the number of seconds by the number of items. This would provide the number of seconds required to run your production for this specific customer's demand.