1. National Guard
Black Belt Training
Module 17
Takt Time

2. UNCLASSIFIED / FOUO
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

3. UNCLASSIFIED / FOUO
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
3
UNCLASSIFIED / FOUO

4. UNCLASSIFIED / FOUO
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
4
UNCLASSIFIED / FOUO

5. UNCLASSIFIED / FOUO
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
5
UNCLASSIFIED / FOUO

6. UNCLASSIFIED / FOUO
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
6
UNCLASSIFIED / FOUO

7. UNCLASSIFIED / FOUO
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!
7
UNCLASSIFIED / FOUO

8. UNCLASSIFIED / FOUO
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!!!”
8
UNCLASSIFIED / FOUO

9. UNCLASSIFIED / FOUO
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
9
UNCLASSIFIED / FOUO

10. UNCLASSIFIED / FOUO
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??
10
UNCLASSIFIED / FOUO

11. UNCLASSIFIED / FOUO
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
11
UNCLASSIFIED / FOUO

12. UNCLASSIFIED / FOUO
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
12
UNCLASSIFIED / FOUO

13. UNCLASSIFIED / FOUO
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
13
UNCLASSIFIED / FOUO

14. UNCLASSIFIED / FOUO
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
14
UNCLASSIFIED / FOUO

15. UNCLASSIFIED / FOUO
What other comments or questions
do you have?
15
UNCLASSIFIED / FOUO