Takt time is an important concept in lean manufacturing. It refers to the rate at which products must be produced in order to meet customer demand. The word “takt” comes from the German word for rhythm or meter.
Calculating Takt Time
Takt time is calculated by dividing the available production time by the rate of customer demand. For example,if customers demand 240 units per day and the available production time is 480 minutes per day,the takt time would be 2 minutes.
Takt Time Formula:
Available Production Time / Customer Demand = Takt Time
So in our example:
480 minutes / 240 units = 2 minute takt time
Why Takt Time Matters
Takt time is a critical metric for aligning production with customer demand. Without using takt time,production may significantly diverge from demand leading to problems. Here are some key reasons why takt time matters:
- It ensures production capacity matches customer requirements. If production capacity is too high,it will result in excess finished goods inventory building up. If capacity is too low,it leads to stockouts and missed sales. Takt time helps right-size capacity.
- It prevents overproduction and excess work-in-progress inventory. Adhering to takt time pulls just enough inventory needed to fulfill demand. Ignoring takt time causes overproduction.
- It creates a consistent cadence or rhythm for production to follow across the plant. This cadence sets the pace for stable and predictable production rather than chaotic,intermittent production.
- It highlights bottlenecks. When a process cannot keep up with takt time,it reveals a bottleneck. Takt time provides this important feedback loop.
- It synchronizes production flow. By balancing workstations to takt time,you create smooth,continuous flow across the whole value stream.
- It reinforces the lean mentality of only producing what the customer demands when they demand it. Takt time connects production decisions directly to customer pull.
Using Takt Time
Takt time provides a rhythm or cadence for production. Lean manufacturing lines are often designed around a takt time. Workstations are spaced to support the rate of customer demand. Takt time can also be used to help balance work between processes and determine optimal batch sizes.
Benefits of Takt Time
- Improves flow by matching production to demand
- Reduces overproduction and excess inventory
- Helps balance workloads across a line
- Sets pace of customer demand through the plant
- Highlights production bottlenecks
In summary,takt time is a simple but powerful concept for aligning production with customer demand. It provides an essential rhythm for lean operations.