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NG BB 17 Takt Time
NG BB 17 Takt Time
NG BB 17 Takt Time
NG BB 17 Takt Time
NG BB 17 Takt Time
NG BB 17 Takt Time
NG BB 17 Takt Time
NG BB 17 Takt Time
NG BB 17 Takt Time
NG BB 17 Takt Time
NG BB 17 Takt Time
NG BB 17 Takt Time
NG BB 17 Takt Time
NG BB 17 Takt Time
NG BB 17 Takt Time
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NG BB 17 Takt Time

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  • 1. National GuardBlack Belt Training Module 17 Takt Time
  • 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. UNCLASSIFIED / FOUO What other comments or questions do you have? 15 UNCLASSIFIED / FOUO

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