Takt time is a key concept in lean manufacturing, which helps optimize production by synchronizing the manufacturing pace with customer demand. In this article, we explain in detail what it is, how to calculate and interpret it, how it differs from cycle time and lead time, as well as the benefits of using it in your plant.
What is takt time ?
The word “takt” comes from German. In music, it means ‘beat’ or ‘tempo’, reflecting the idea of a regular production rhythm. In a factory, takt time is the rate at which a product must be manufactured to meet customer demand.
The concept was developed by Toyota engineers in the 1950s as part of the Toyota Production System (TPS), the forerunner of lean manufacturing. Its aim is to synchronize production with actual customer demand, in order to avoid waste, or muda (overproduction, inventory, etc.).
What are the differences between Takt Time, Cycle Time, and Lead Time?
- Takt time, as we have just seen, is the rate at which a product must be manufactured to meet customer demand over a given period.
- Cycle time is the time it takes to produce a unit, from raw material input to finished product output.
- Lead time is the total elapsed time between the launch of a manufacturing order and the delivery of the finished product to the customer.
While cycle time and lead time are internal performance measurements, takt time is related to external customer demand.
How to calculate takt time ?
Takt time is calculated as follows:
Available work time per period / Customer demand over the period
Let’s take the example of a company that produces pens. And let’s imagine that we have a working day of 8 hours, minus a 1.5-hour break, i.e. 6.5 hours (390 minutes).
If the customer demand is 390 pens per day, the calculation will be:
390 minutes / 390 pens
= 1 minute per pen
If, as in the example, the takt time is 1 minute, it means that, to meet the demand, the company must produce at least one pen every minute.
Determine the required production capacity using cycle time
By comparing takt time to cycle time, we can determine if production capacity is sufficient to meet demand:
- If cycle time is shorter than takt time, capacity exceeds demand. There is a risk of overproduction.
- If cycle time is equal to takt time, capacity matches demand. That is the ideal scenario.
- If cycle time is greater than takt time, capacity is below demand. Resources need to be increased, or the process optimized.
The aim is to align cycle time and takt time by adjusting your production capacity to eliminate waste.
Takt time : what for ?
Matching production rates as closely as possible to actual customer demand is not the only advantage of introducing this indicator to your production process. Here are some more reasons to monitor this valuable indicator:
- Optimize resources : by knowing precisely the necessary production pace, it is possible to better schedule human and material resources, thus reducing operational costs.
- Reduce delivery times : by producing in line with demand, delivery times are shorter and more predictable.
- Increase flexibility : it allows production to be adjusted quickly in line with changing demand, providing greater responsiveness to market changes.
- Facilitate continuous improvement : By regularly measuring this indicator, companies can identify bottlenecks and inefficiencies in the production process, thereby facilitating continuous improvement initiatives.
Production benefits
There are many advantages to implementing takt time in your plant:
- Reduce costs : by avoiding overproduction and optimizing resource use, inventory, scrap and overtime costs are considerably reduced.
- Productivity gains : it eliminates waste identified in lean manufacturing, such as waiting time, unnecessary movements and overproduction. This leads to more efficient use of resources, and increased productivity.
- Improve quality : by stabilizing the production rate, processes become more predictable and manageable, reducing variations and quality defects. Operators can focus on quality rather than quantity.
- Increase customer satisfaction : by producing exactly what is needed, when it is needed, companies can respond more quickly and accurately to customer needs, boosting customer satisfaction and loyalty.
- Motivate your employees : working with clear and realistic targets, such as takt time, can motivate production teams. This fosters a collaborative working environment, where each member understands his or her role in achieving production targets.
- Ensure visibility and transparency : this tool provides a clear and simple measurement of production performance, facilitating communication and decision-making at all levels of the organization.
- Reduce risk : by producing in line with demand, companies reduce the risks associated with obsolete stock and unforeseen fluctuations in demand.
In conclusion, takt time is an essential tool for any company that is looking to optimize its production processes, reduce costs and improve customer satisfaction. Calculating this production indicator enables you to align your production flows with actual demand. By integrating this tool into your production strategy, you can not only improve your operational efficiency, but also strengthen your competitive position in the market.
