ng bb 17 takt time
TRANSCRIPT
National GuardBlack Belt Training
Module 17
Takt Time
UNCLASSIFIED / FOUO
UNCLASSIFIED / FOUO
2
CPI Roadmap – Measure
Note: Activities and tools vary by project. Lists provided here are not necessarily all-inclusive.
TOOLS
•Process Mapping
•Process Cycle Efficiency/TOC
•Little’s Law
•Operational Definitions
•Data Collection Plan
•Statistical Sampling
•Measurement System Analysis
•TPM
•Generic Pull
•Setup Reduction
•Control Charts
•Histograms
•Constraint Identification
•Process Capability
ACTIVITIES• Map Current Process / Go & See
• Identify Key Input, Process, Output Metrics
• Develop Operational Definitions
• Develop Data Collection Plan
• Validate Measurement System
• Collect Baseline Data
• Identify Performance Gaps
• Estimate Financial/Operational Benefits
• Determine Process Stability/Capability
• Complete Measure Tollgate
1.Validate the
Problem
4. Determine Root
Cause
3. Set Improvement
Targets
5. Develop Counter-
Measures
6. See Counter-MeasuresThrough
2. IdentifyPerformance
Gaps
7. Confirm Results
& Process
8. StandardizeSuccessfulProcesses
Define Measure Analyze ControlImprove
8-STEP PROCESS
UNCLASSIFIED / FOUO
UNCLASSIFIED / FOUO
3
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
Objectives
UNCLASSIFIED / FOUO
UNCLASSIFIED / FOUO
4
Time required to produce a component or set of components to meet customer demand
Subject to change – depending on demand from the customer
Determines rate of production
Key to determining resource requirements
Takt Time =Operating Time
Customer Requirements
Definition of Takt Time
UNCLASSIFIED / FOUO
UNCLASSIFIED / FOUO
5
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
Takt Time Example – Step 1
UNCLASSIFIED / FOUO
UNCLASSIFIED / FOUO
6
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
Takt Time Example – Step 2
UNCLASSIFIED / FOUO
UNCLASSIFIED / FOUO
7
Divide operating time by demand
15600 minutes/year divided by 3,120 units/year
Takt time =
This is the time that each process step CANNOT
exceed in order to meet customer demand using
single piece flow!
5 minutes (300 seconds)
Takt Time Example – Step 3
UNCLASSIFIED / FOUO
UNCLASSIFIED / FOUO
8
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!!!”
Takt Time vs. Cycle Time
UNCLASSIFIED / FOUO
UNCLASSIFIED / FOUO
9
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
TAKT TIME= MINIMUM STAFF REQUIRED
Takt Time & Theoretical Minimum Staffing
UNCLASSIFIED / FOUO
UNCLASSIFIED / FOUO
10
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?
In your experience, what are some of the practical issues
that make it difficult to hit this minimum staffing??
720 sec/300 sec = 2.4 …so 3 People
Theoretical Minimum Staffing - Example
UNCLASSIFIED / FOUO
UNCLASSIFIED / FOUO
11
70
40
15
45
30
0
20
40
60
80
Oper.1 Oper.2 Oper.3 Oper.4 Oper.5
Operator Cycle Time in
Seconds/Part
Takt Time = 60 Sec
Takt Time – Cycle Time Bar Charts enable us to visualize a
production line with data and determine some of its
operating characteristics
Let’s look at a sample chart
Cycle Time Bar Charts
UNCLASSIFIED / FOUO
UNCLASSIFIED / FOUO
12
60 60 60
20
0
20
40
60
80
Oper.1 Oper.2 Oper.3 Oper.4
Operator Cycle Time in
Seconds/Part
Takt Time = 60 Sec
Cycle Time Bar Chart - After
UNCLASSIFIED / FOUO
UNCLASSIFIED / FOUO
13
60 60 60
0
20
40
60
80
Oper.1 Oper.2 Oper.3
Operator Cycle Time in
Seconds/Part
Takt Time = 60 Sec
Cycle Time Bar Chart - Final
UNCLASSIFIED / FOUO
UNCLASSIFIED / FOUO
14
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
Takeaways
UNCLASSIFIED / FOUO
UNCLASSIFIED / FOUO
15
What other comments or questions
do you have?