Takt Time is a cycle time in which production activities are carried out to meet customer needs, reflecting the time spent on production.
Measurement of man-hours Man-hours: How much time it takes a qualified operator to complete the work is defined, it includes three aspects: process time, such as testing, reinforcement, etc. Basic time, and manual work time…
Measurement of work hours
Man-hours: How much time it takes a qualified operator to complete the job, defined in three areas:
- Process time, e.g. testing, hardening, etc.
- Basic time, and manual work time.
The time when personal factors arise, such as psychological fatigue, personal physiological fatigue, etc.
Working hours are measured by the following means, such as stopwatch method, MTM measurement method.
Measuring work hours can do the following:
- It is a standard for studying labor and productive capacity.
- It is possible to improve and increase labor productivity.
- It can be used as the basis for the decision-making of managers.
Look at lean from the word ” work “
Self-sufficiency in lean refers to the automation of self-disciplined control of abnormal situations and human judgement.
This is a device that discovers abnormalities or defects. And a device that can stop the production line or equipment when these abnormalities or defects occur.
It contains a mechanism that prevents a non-conforming part from passing through the production line when it is found.
So the following effects can be achieved:
- Because of self-servicing, there is no need for personnel to monitor abnormal situations. Which can reduce the number of workers, thereby achieving the purpose of reducing costs.
- Since the parts and equipment required for production can be stopped. The parts produced are all qualified products, the inventory can be reduced, and production can be synchronized.
This self-improvement requires continuous improvement of equipment and the environment, stimulates the initiative of employees, and thus strengthens respect for personality.
What is mobile production? : Production Cycle Time
Flow production is a set of production and processing methods based on time control. Which pulls materials through the production system without stagnation according to customer requirements.
At the same time, logistics are synchronously transported to the main production system through the secondary production system, so that raw materials and work-in-process can quickly become finished products.
So why is it important to focus on time control?
Because the time lost in the organization of materials affects the production management cost and the cash flow in production. Material handling requires sufficient space, monitoring systems, handling and transportation, and many other links that increase the production cost of the product at each step.
Flow production reduces intermediate links and synchronizes production, so that materials can pass through each value-added processing process without hindrance, achieving the purpose of reducing management / control costs. When the total production cycle time is reduced, the factory’s ability to respond to changes in customer needs will also be significantly improved. The root cause is its fast, efficient and low-cost material transportation capabilities.
What is Total Product Cycle Time?
The total production cycle (TPc/t) is a unit of measurement for the production flow. It is defined as the maximum lead time of a product, i.e. the elapsed time from the acceptance of the initial raw material to the shipment of the final finished product.
Synchronous processing
Flow production must synchronize the individual steps of the production process to reduce TPc/t (total production cycle). Which can be achieved by physically connecting the processes in a buffered way (first in, first out) or by establishing a pull system.
Production synchronization is based on an understanding of the various elements of the operation of people and equipment and balances customer needs through smooth production.
What is a value stream map:
Value Stream Mapping (VSM) is a sequential transfer process of value stream data in the form of a file and using icons to represent the flow of information in a graphical table.
A value stream encompasses all elements (both value-added and non-value-added). That originate from a particular product, starting with raw materials and delivering the finished product to the user.
Why value stream mapping:
For a long time, people have been considering reducing costs from the perspective of the product itself in the production process of enterprises. This approach now seems to have little leeway.
Costs arise in all aspects of the product (or service) production process, and are accompanied by the creation of new value and the consumption of various resources in the flow of people, logistics, information and capital.
Therefore, there are more cost control space and opportunities in the value stream of the value chain, and only through the analysis of the value stream of the enterprise can cost control be effectively achieved.
The mapping and analysis of value stream maps is the beginning of building a lean enterprise. Through the value stream, the management, engineering department, production department, upstream supplier, downstream customer can recognize and identify waste. By depicting old value stream maps, new optimized value stream maps can be constructed. Optimizing value stream mapping is the basis for lean system design.
What is Takt Time?
Takt Time is a cycle time in which production activities are carried out to meet customer needs, reflecting the time spent on production of a production line or production equipment corresponding to the customer’s needs.
By identifying Takt Time, it will help companies better refine their methods of synchronizing customer needs with production rates.
How to determine Takt Time?
Determine the process involved in meeting the customer’s overall demand.
Carefully certify accurate requirements information, taking into account batch sizes. If the production is diversified on the same equipment, this compound demand should also be counted in the Takt Time.
The production capacity plan needs to be adapt to the level of demand. The production level can link to the equipment design capacity. Capacity levels are express in Lean Capacity Rate, Max Capacity and Flex Capacity Rate. The Fine Capacity Rate calculates the daily productivity (measured in five working hours a week) based on the capacity of the assembly shop for one week. Which can use to determine the 120 hours of production time per week corresponding to customer demand.
The maximum capacity is the upper limit of the total production capacity of the production platform in one week. The elastic capacity ratio reflects the status of mixed flow production. The published maximum capacity and flexible capacity ratio can reasonably determine the maximum demand value. The greater output can be obtain through certain methods. (such as overtime, rotating work schedules, increasing foreign labor, etc.).
These means can be used to confirm capacity in certain production departments with unstable volumes.
In addition to production planning, the production department needs to be given more detailed information in response to the diversity of requirements and the requirements of mixed flow production. Sources of this information include:
- Material planning (including material movement)
- Industrial engineering budget
- Production control (monthly/weekly forecast)
- Production records (daily and monthly production changes)
- Sales (production changes, new business, etc.)
Detailed audit of the source and accuracy of information, and solve data discrepancies through investigation and research.
Determine the planned running time of the production process segment:
Scheduled Runtime = Effective Minutes – (Planned Downtime)
Effective time = (Minute per shift per shift) – (actual interruption time approved breaks)
Planned downtime is the time elapsed to stop an operation for a planned reason.
Calculate Takt Time:
Takt Time = Planned Operating Time / Total Customer Demand.