Takt Time - Lean Six Sigma

1 takt time Training PackWhich of these is Important to Our business? Satisfied Customers Profit Growth Market Share Effective use of its people and plant Maximum Capacity ProductionWhy Not Maximum Capacity?Producing more than the customer requires is:This is the greatest of the Seven WastesAs it leads to occurrence of the other sixOVER-PRODUCTIONThe Western ApproachWe produce more than we require to allow for problemsThis embeds waste in our business123 Push production SystemCustomerIf we consider production operations as a link producing in isolation at full speed will cause a mismatch between linksSome areas over-produce, some cannot keep ? Push production SystemCustomerWhat will happen when a link in the chain breaksWithin a Push System? Push production SystemCustomerThe individual links keep building to schedule chain soon backs up Push production SystemCustomerWhen we consider the wider see why stock is present.

2 To bufferthe unevenness of work To bufferthe breaks in the chainSTOCK / WIPJust In TimeTakt TimeTakt TimeJITPull systemConti n uo us Flow Pr ocessi n gLevel Sche dul i n gThe Just in time branch of theLean production Systemis constructed of four key elementsTakt TimeTakt is a German wordIt is the principal that all activity within a business issynchronised by a pulse, set by the customerdemandIt describes the conductorsbatonTakt time determines;The pulse of the production System Pace of sales Links production activity to actual customer demand Ensures all production activity will be synchronisedfrom 1st process to final assembly process. - FLOWTakt time relates the customer demand to the time = production time AvailableCustomer DemandTime is deducted for:Lunch and tea breaksTeam briefing timesTPM breaksClean down 8hrs x 60 = 480 minutes time Available= 480 20 mins breaks 10 mins TPM = 450minsHow To Calculate takt TimeIf the customer demand is 500 units per week;Demand = 500 / 5= 100 products a dayTakt time = time AvailableCustomer Demand=450 mins100= mins or 270 secsHow To Calculate takt TimeTakt, Cycle, Target Cycle and Lead TimeTakt time = The pace at which the customer requires productsTarget Cycle time =The pace at which we will produce to ensure we meet the customer requirementsCycle time =The time at which a process cyclesLead time = The total production lead time from product start to finishDon t get them confused!

3 ! takt , Cycle, Target Cycle and Lead TimeTakt TimeTarget CycleTimeCycleTime+++++ =LeadTimeFlow ProductionCustomerThe customer takes a product from the endOf the chainEach link in the chain takes from the previous linkAnd processes produce to fill the gap that has beencreatedWhat will happen when a link in the chain breaksCustomerFlow ProductionIf a link in the chain chain the Customer does not pull from the chain time , an enabler for FlowIf work balance is set to takt , the process closest thecustomer can pull production through the system atthe right pace. This includes material pull removes the requirement for scheduling ateach stage, and hence the buffer stocks and WorkIn Progress that populate the Push Process , an Enabler for work BalanceMug TreeCoffeeBoilerFridge16543721 Obtain Mug2 Put Mug DownObtain SpoonPut Coffee in Mug3 Obtain Milk4 Put Milk in Mug5 Return Milk6 Add Water to MugPick up Mug7 Place Mug on TableOPNoNo work DescriptionStepTimeWorkWalkC012282224244 214223 TOTALS45 18633C03C05C02C04C06 Return5440 minutes/day X 60 seconds/minute380 products per day=66 SecsThe Customer Requires.

4 380 Mugs of Coffee / dayTime AvailableCustomer Demand= takt TIMETakt, an Enabler for work BalanceTakt, an Enabler for work BalanceTakt, an Enabler for work BalanceTakt, an Enabler for work BalanceTakt, an Enabler for work BalanceTakt, an Enabler for work BalanceTakt, an Enabler for work BalanceTakt, an Enabler for work BalanceTime Available = 480mins - 30mins breaks - 10mins team meeting66 Secs TAKTNon Value AddedValue AddedC01C02C06C03(Add Coffee)C04 Add MilkC05(Add Water) takt , an Enabler for work BalanceTakt, an Enabler for work BalanceTakt, an Enabler for work BalanceTakt, an Enabler for work BalanceTakt, an Enabler for work BalanceTakt, an Enabler for work BalanceTakt, an Enabler for work BalanceTakt, an Enabler for work BalanceOpNo7 Secs2 Secs8 Secs2 Secs8 Secs4 Secs14 Secs12 SecsTakt, an Enabler for work BalanceTakt, an Enabler for work BalanceTakt, an Enabler for work BalanceTakt, an Enabler for work BalanceTakt, an Enabler for work BalanceTakt, an Enabler for work BalanceTakt, an Enabler for work BalanceTakt, an Enabler for work BalanceHow do we use this information to meet ourcustomer demand?

5 Add 20% more workers?Run 20% Overtime?Contract out 76 cups of coffee to a supplier?Use takt to drive waste eliminationCustomer Demand +20%380 mugs / day to 456 mugs / day380 Mugs of Coffee440 X 60380=66 SecsTAKTWhen Customer requirements change, takt changesTakt, an Enabler for work BalanceTakt, an Enabler for work BalanceTakt, an Enabler for work BalanceTakt, an Enabler for work BalanceTakt, an Enabler for work BalanceTakt, an Enabler for work BalanceTakt, an Enabler for work BalanceTakt, an Enabler for work Balance456 Mugs of Coffee440 X 60456=55 SecsTAKT66 SecsNon Value AddedValue AddedC01C02C03C04C05 takt for 380 mugs / dayC0655 SecsTakt for 456 mugs / dayTakt, an Enabler for work BalanceTakt, an Enabler for work BalanceTakt, an Enabler for work BalanceTakt, an Enabler for work BalanceTakt, an Enabler for work BalanceTakt, an Enabler for work BalanceTakt, an Enabler for work BalanceTakt.

6 An Enabler for work BalanceMug TreeCoffeeBoilerFridge16543721 Obtain Mug2 Put Mug DownObtain SpoonPut Coffee in Mug3 Obtain Milk4 Put Milk in Mug5 Return Milk6 Add Water to MugPick up Mug7 Place Mug on TableOpNoNo work DescriptionStepTimeWorkWalkC012282224244 214223 TOTALS45 18633C03C05C02C04C06 Return5 takt , an Enabler for work BalanceWork BalanceWork Package Progress TrackerA work package progress tracker will be used to monitor how the unit build is progressing against takt and drive corrective action1234567891234567891011121314151617 OperatorCycle TimeTakt TimeTask DescriptionUnitStart dateStart TimeTarget finishWORKPACKAGE 1 PACKAGE PROGRESS TRACKERRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot

7 End chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end

8 Chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsRoot end chop lugsTakt TimeCustomerSTOCK / WIPREMEMBER WASTE, ITS DOOMWe know why conventional western methods will make our business unprofitableWASTETakt TimeEnables work -balancingEnables FlowDriving out waste within our business