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Takt Time - Lean Six Sigma
Takt Time Training Pack Which of these is Important to Our business? • • • • • • Satisfied Customers Profit Growth Market Share Effective use of its people and plant Maximum Capacity Production Why Not Maximum Capacity? Producing more than the customer requires is: OVER-PRODUCTION This is the greatest of the Seven Wastes As it leads to occurrence of the other six The Western Approach We produce more than we require to allow for problems 1 2 3 This embeds waste in our business ‘Push’ Production System If we consider production operations as a chain… ? Customer Each link producing in isolation at full speed will cause a mismatch between links Some areas over-produce, some cannot keep up... ‘Push’ Production System Customer What will happen when a link in the chain breaks Within a ‘Push’ System? ‘Push’ Production System The individual links keep building to schedule and… Customer The chain soon backs up ‘Push’ Production System When we consider the wider system… Customer STOCK / WIP We see why stock is present. To buffer the unevenness of work To buffer the breaks in the chain Just In Time JIT The Just in Time branch of the Lean Production System Pull system Contin uo us Flow Processin g Takt Time Level Sche dulin g is constructed of four key elements Takt Time Takt is a German word It describes the conductors baton It is the principal that all activity within a business is synchronised by a pulse, set by the customer demand Takt Time determines; The pulse of the Production System •Pace of sales •Links production activity to actual customer demand •Ensures all production activity will be synchronised from 1st process to final assembly process. - FLOW How To Calculate Takt Time Takt time relates the customer demand to the time available. Takt = Production Time Available Customer Demand Time is deducted for: Lunch and tea breaks Team briefing times TPM breaks Clean down time E.g 8hrs x 60 Time Available = 480 minutes = 480 – 20 mins breaks – 10 mins TPM = 450mins How To Calculate Takt Time If the customer demand is 500 units per week; Demand = 500 / 5 = 100 products a day Takt Time = Time Available Customer Demand = 450 mins 100 = 4.5 mins or 270 secs Takt, Cycle, Target Cycle and Lead Time Takt Time = The pace at which the customer requires products Target Cycle Time = The pace at which we will produce to ensure we meet the customer requirements Cycle Time = The time at which a process cycles Lead Time = The total production lead time from product start to finish Don’t get them confused!! Takt, Cycle, Target Cycle and Lead Time Cycle Time Takt Time Target Cycle Time + + + + + = Lead Time Flow Production Customer The customer takestakes a product from the endlink Each link in the chain from the previous Of the And processes produce to chain fill the gap that has been created What will happen when a link in the chain breaks Flow Production Customer If a link in the chain breaks... The chain stops. If the Customer does not pull from the end... The chain stops. Takt Time, an enabler for Flow If work balance is set to Takt, the process closest the customer can pull production through the system at the right pace. This includes material delivery. This pull removes the requirement for scheduling at each stage, and hence the buffer stocks and Work In Progress that populate the ‘Push’ Process Chain. Takt, an Enabler for Work Balance 1 2 3 4 C01 Obtain Mug Put Mug Down Obtain Spoon Put Coffee in Mug Obtain Milk Time 2 2 C02 2 C03 8 C04 Put Milk in Mug Walk OP No Work Step No Work Description 3 Mug Tree 1 2 Coffee 2 Boiler 4 4 Fridge 2 5 Return Milk 6 Add Water to Mug Pick up Mug 7 4 C05 14 C06 2 Place Mug on Table 2 2 2 3 Return 4 3 6 5 5 7 TOTALS 63 45 18 Takt, an Enabler for Work Balance The Customer Requires: 380 Mugs of Coffee / day TAKT TIME = Time Available Customer Demand Time Available = 480mins - 30mins breaks - 10mins team meeting 440 minutes/day X 60 seconds/minute 380 products per day = 66 Secs Takt, an Enabler for Work Balance 66 Secs TAKT 12 Secs C06 14 Secs Value Added C05 (Add Water) Add Milk 4 Secs 8 Secs Non Value Added C04 C03 (Add Coffee) C02 C01 2 Secs 8 Secs 2 Secs 7 Secs Op No Takt, an Enabler for Work Balance Customer Demand +20% 380 mugs / day to 456 mugs / day How do we use this information to meet our customer demand? Add 20% more workers? Run 20% Overtime? Contract out 76 cups of coffee to a supplier? Use Takt to drive waste elimination Takt, an Enabler for Work Balance When Customer requirements change, Takt changes 380 Mugs of Coffee 456 Mugs of Coffee 440 X 60 = 66 Secs 380 TAKT 440 X 60 = 55 Secs 456 TAKT Takt, an Enabler for Work Balance C06 66 Secs Takt for 380 mugs / day 55 Secs Takt for 456 mugs / day C05 C04 C03 Non Value Added C02 C01 Value Added Takt, an Enabler for Work Balance 1 2 3 4 C01 Obtain Mug Put Mug Down Obtain Spoon Put Coffee in Mug Obtain Milk Time 2 2 C02 2 C03 8 C04 Put Milk in Mug Walk Op No Work Step No Work Description 3 Mug Tree 1 2 Coffee 2 Boiler 4 4 Fridge 2 5 Return Milk 6 Add Water to Mug Pick up Mug 7 4 C05 14 C06 2 Place Mug on Table 2 2 2 3 Return 4 3 6 5 5 7 TOTALS 63 45 18 Work Balance Work Package Progress Tracker WORKPACKAGE 1 PACKAGE PROGRESS TRACKER Task Description Unit Start date 1 1 Operator 2 3 4 5 6 7 8 9 2 3 Root end chop lugs Root end chop Root lugs end chop lugs Root end chop lugs Root end chop lugs Root end chop Root lugs end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop Root lugs end chop lugs Root end chop Root lugs end Root end chop lugs Root end chop lugs chop lugs Root end chop Root lugs end chop lugs Root end chop lugs Root end chop Root lugs end Root end chop lugs chop lugs Root end chop lugs Root end chop Root lugs end chop lugs Root end chop lugs Root end chop lugs Root end chop Root lugs end chop lugs Root end chop lugs Root end chop lugs Root end chop Root lugs end chop lugs Root end chop lugs Start Time 4 Cycle Time Target finish 5 6 Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs 7 Root end chop lugs 8 Root end chop lugs 9 Root end chop lugs 10 Root end chop lugs 11 Root end chop lugs 12 Root end chop lugs 13 Root end chop lugs 14 15 16 17 Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs Root end chop lugs A work package progress tracker will be used to monitor how the unit build is progressing against takt and drive corrective action Takt Time Takt Time We know why conventional western methods will make our business unprofitable Customer STOCK / WIP REMEMBER WASTE, ITS DOOM Takt Time Enables work-balancing Enables Flow WASTE Driving out waste within our business
