NG BB 17 Takt Time

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NG BB 17 Takt Time

  1. 1. National GuardBlack Belt Training Module 17 Takt Time
  2. 2. UNCLASSIFIED / FOUOCPI Roadmap – Measure 8-STEP PROCESS 6. See 1.Validate 2. Identify 3. Set 4. Determine 5. Develop 7. Confirm 8. Standardize Counter- the Performance Improvement Root Counter- Results Successful Measures Problem Gaps Targets Cause Measures & Process Processes Through Define Measure Analyze Improve Control TOOLS •Process Mapping ACTIVITIES • Map Current Process / Go & See •Process Cycle Efficiency/TOC • Identify Key Input, Process, Output Metrics •Little’s Law • Develop Operational Definitions •Operational Definitions • Develop Data Collection Plan •Data Collection Plan • Validate Measurement System •Statistical Sampling • Collect Baseline Data •Measurement System Analysis • Identify Performance Gaps •TPM • Estimate Financial/Operational Benefits •Generic Pull • Determine Process Stability/Capability •Setup Reduction • Complete Measure Tollgate •Control Charts •Histograms •Constraint Identification •Process Capability 2 Note: Activities and tools vary by project. Lists provided here are not necessarily all-inclusive. UNCLASSIFIED / FOUO
  3. 3. UNCLASSIFIED / FOUOObjectives  Understand the following: – Takt Time – Theoretical minimum staffing levels – Takt Time, Cycle Time Bar Charts – How all of these concepts assist in understanding and improving a process 3 UNCLASSIFIED / FOUO
  4. 4. UNCLASSIFIED / FOUODefinition of Takt Time  Time required to produce a component or set of components to meet customer demand Operating Time Takt Time = Customer Requirements  Subject to change – depending on demand from the customer  Determines rate of production  Key to determining resource requirements 4 UNCLASSIFIED / FOUO
  5. 5. UNCLASSIFIED / FOUOTakt Time Example – Step 1 Step 1: Determine available time  Aircrew Flight Equipment (AFE) has 1 hour a day to test life vests 52 (weeks) * 5 (days/week) * 1 hour = 260 hours  Convert to minutes 260 hours * 60 minutes/hour = 15,600 minutes Answer: 15,600 minutes is the total available operating time per year 5 UNCLASSIFIED / FOUO
  6. 6. UNCLASSIFIED / FOUOTakt Time Example – Step 2  Step 2: Determine Customer Requirement – Average daily customer demand – Get this anyway you can • Advance orders • Forecasts • Historical data • Best guess! – For this example, AFE has 3,120 life vests to maintain 3,120 units per year is the customer requirement 6 UNCLASSIFIED / FOUO
  7. 7. UNCLASSIFIED / FOUOTakt Time Example – Step 3  Divide operating time by demand 15600 minutes/year divided by 3,120 units/year  Takt time = 5 minutes (300 seconds)  This is the time that each process step CANNOT exceed in order to meet customer demand using single piece flow! 7 UNCLASSIFIED / FOUO
  8. 8. UNCLASSIFIED / FOUOTakt Time vs. Cycle Time  Cycle time is the time for an operator to do a prescribed task and return to his or her original stance  Don’t confuse cycle time and Takt Time!! WHAT’S WRONG WITH THIS QUOTE ?? “Those people have Takt time down to a science! Their Takt time is 54 seconds. They make a car in 54 seconds and every step in the process takes 54 seconds. And they have a plan to reduce their Takt time to 52 seconds through constantly improving every job! Amazing!!!” 8 UNCLASSIFIED / FOUO
  9. 9. UNCLASSIFIED / FOUOTakt Time & Theoretical Minimum Staffing If we: • Understand the Total Cycle Time required to produce a unit, and we have • Calculated the Takt Time of this unit  We can calculate the theoretical minimum staffing required. This is calculated as: TOTAL CYCLE TIME = MINIMUM STAFF REQUIRED TAKT TIME 9 UNCLASSIFIED / FOUO
  10. 10. UNCLASSIFIED / FOUOTheoretical Minimum Staffing - Example If the Total Cycle Time of all the operators combined = 720 seconds AND The Takt Time is 300 seconds WHAT IS THE MINIMUM STAFFING REQUIREMENT FOR LIFE VESTS IN AFE? 720 sec/300 sec = 2.4 …so 3 People In your experience, what are some of the practical issues that make it difficult to hit this minimum staffing?? 10 UNCLASSIFIED / FOUO
  11. 11. UNCLASSIFIED / FOUOCycle Time Bar Charts Takt Time – Cycle Time Bar Charts enable us to visualize a production line with data and determine some of its operating characteristics Operator Cycle Time in Seconds/Part Let’s look at a sample chart 80 70 Takt Time = 60 Sec 60 45 40 40 30 20 15 0 Oper.1 Oper.2 Oper.3 Oper.4 Oper.5 11 UNCLASSIFIED / FOUO
  12. 12. UNCLASSIFIED / FOUOCycle Time Bar Chart - After Operator Cycle Time in Seconds/Part 80 Takt Time = 60 Sec 60 60 60 60 40 20 20 0 Oper.1 Oper.2 Oper.3 Oper.4 12 UNCLASSIFIED / FOUO
  13. 13. UNCLASSIFIED / FOUOCycle Time Bar Chart - Final Operator Cycle Time in Seconds/Part 80 Takt Time = 60 Sec 60 60 60 60 40 20 0 Oper.1 Oper.2 Oper.3 13 UNCLASSIFIED / FOUO
  14. 14. UNCLASSIFIED / FOUOTakeaways  Takt Time is based on customer demand – it is the time in which a task must be completed to meet the customer requirements  Cycle time is the time it takes to actually complete the task  Use takt time and cycle time to determine theoretical minimum staffing levels  Visually display staffing levels using Cycle Time Bar Charts to help improve the process 14 UNCLASSIFIED / FOUO
  15. 15. UNCLASSIFIED / FOUO What other comments or questions do you have? 15 UNCLASSIFIED / FOUO

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