Process engineering TAKT times

Takt is a German word which refers to the beat of music. What is Takt? Takt is a German word which refers to the beat of music. During the 1930's, Germany and Japan were part of the Axis and German engineers helped organise the Japanese aircraft industry. After the war, Toyota picked up the word and used it in the Toyota Production System.

What is TAKT time? Takt time is the maximum time allowed to produce a product in order to meet demand. Product flow is expected to fall within a pace/cycle that is less than or equal to the takt time. In a lean manufacturing environment, the pace time is set equal to the takt time. Sourced Wikipedia

Information required How many units are needed by the customer per year? How many days do you intend to work per year? What number of hours are worked each shift? How many shifts are there in a day? What is the rate of efficiency?

Efficiency formula Efficiency = Actual number of hours worked per shift (minus breaks etc). Total number hours at work/shift less total time for: breaks fatigue maintenance activities other activities.

Calculate TAKT _____________________________ time = Available daily work time less inefficiencies TAKT _____________________________ time = Daily product requirement (required quantity)

Customer requirements Customer requirement: 60 cars in 1 Hour (60 minutes) 60 Mins Customer requirement = 60 Cars = 1 (min per car)

Customer requirements Customer requirement: 120 cars in 1 Hour (60 minutes) 60 Mins Customer requirement = 20 Cars = 0.5 (min per car)

Work day efficiency Planned inefficiencies = 8 hours – 85 minutes 8 hours at work per day less: 30 minutes lunch 2 x 15 minute smoko (am/pm) 10 minutes cleaning 10 minutes maintenance activity 5 minute fatigue factor. = 8 hours – 85 minutes Note: Unplanned inefficiencies are also a factor. Discuss unplanned inefficiencies acquired from historical data

Calculation Detail required How many units need to be produced? 22000 units per annum required How many days are worked per year? 220 days worked per year How many shifts are worked per day? 2 shifts per day How many hours are worked per shift? 8 hours per shift What is the efficiency % rate?

Calculation formula Number of units per annum 22000 Number of days 220 = 100 units per day Number of units per day 100 Number of hours worked per day 16 = 6.25 units per day (6.25 units per hour: Contingency plan – never go down!)

Calculation results 6.25 units per hour = 1 unit every 8.6 minute or = 1 unit every 516 seconds The process in total must be able to accommodate this considering efficiency. Unit numbers changed to 7 only complete units rounded up

Work day efficiency calculation = 480 minutes – 85 minutes = 395 minutes available working time Therefore efficiency in this example is less. 395 480 x 100 = 82.29% Note: The industry standard is approximately 85%. 85 mins = smoko, lunch, breaks

Efficiency relative to TAKT time Consider the following: = 6.25 units per hour required (This rate of production would not be high enough, we need to incorporate the efficiency rate.) 6.25 units per hour at 82.29% efficiency 6.25 100 x 82.29% = 5.14

Improving process efficiency To meet output required per shift/year: 6.25 units/hour x 100% - 82.29% Actual output required per hour = 8.2 units/hour Time in seconds (1 hour) 3600 Units per hour 8.2 = 439 seconds TAKT time TAKT time is equal to or less than the calculated result.