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CPI 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
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Objectives
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
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Definition 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
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Takt 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
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Takt 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
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Takt 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!
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Takt 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!!!”
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Takt 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
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Theoretical 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??
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Cycle 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
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Cycle 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
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Cycle 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
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Takeaways
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
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What other comments or questions
do you have?
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