CALCULATE THE TAKT TIME
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To avoid overproduction and optimize processes.
The Takt time is the time it takes for customers to consume a product. It is the rhythm of sale, and use it as "pacemaker" for production avoids shortages, if we produce at the speed of the demand, and overproduction otherwise. Takt time is the first necessary data to organize just in time production.
Permit to avoid over production
Help to synchronize processes
Help to detect Mudas.
To calculate the takt time it is necessary to know the quantity to be produced and the opening time of the production.
Calculate the takt time by dividing the opening time of the reference period by the number of products sold in the same period. In the opening time of production you must not include the allowed non-production times, ie break times, meetings, change-over, etc. Do not put a safety coefficient for the defects, this would mean to standardizing the anomalies, and the detection of the mudas will be more difficult.
Perform this calculation on a monthly basis to ensure the availability of resources, including staffing. For example, for an order of 8400 products in the month (140 hours available), the takt time is 140h x 3600 seconds / 8400 = 60 seconds. That is 420 products per day. If several products are manufactured on the same line, with different quantities and times, the calculation of an average takt time is not significant. You have to calculate a takt time per product. Prefer the highest level of leveling possible, eg make all models every day. Thus, stocks are reduced, the consumption of components is smoothed and the flexibility is maximum from upstream to downstream.
Calculate the manpower required for a production by dividing the work content (= total assembly time) of a product by takt time. For example, if the takt time is 60 seconds and the total assembly time is 900 seconds we will need 15 operators.
Then the objective is to continuously reduce the gap between the cycle time (including the production aleas) and the takt time.
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