In previous blogs, we have extensively covered the terms cycle time and lead time. Now, it is time to discuss takt time. Takt time is a crucial metric that you can easily calculate yourself, and it can greatly benefit your production processes. Let’s dive into the key questions: What is takt time? And how can you calculate it?
What does takt time mean?
Simply put, takt time is the maximum available time per unit to meet customer demand. This time can vary significantly—ranging from just a few seconds for large-scale manufacturers to several minutes for custom-made products. By understanding takt time, you can better align your production processes, preventing both overproduction and shortages. The calculated takt time indicates whether your organization is operating faster or slower than the theoretical production time. If actual production time per unit exceeds takt time → delays will occur. If actual production time per unit is shorter than takt time → there may be overcapacity or inefficiencies. Takt time is a key concept in lean manufacturing and just-in-time (JIT) production, as it helps to create an efficient workflow.
What do you need to calculate takt time?
Before you can calculate the takt time for your process, you need two essential data sources. First, you must clearly define the available production time. This is the total time a production line or process has to operate within a given period (such as a shift or a day). Keep in mind that any downtime due to breaks or malfunctions should not be included. Second, you need insight into customer demand (or sales volume). This includes the number of products or services that need to be delivered within the same period to meet customer demand. This could, for example, be the number of orders per day. Once you have a clear understanding of both the available production time and customer demand, you can calculate the takt time.
Example of a takt time formula
Filling in a takt time formula is quite simple. If you know the available production time and customer demand, you simply enter these values to complete the formula. For example, suppose a factory operates day shifts of 8 hours. This equals 480 minutes, from which a 30-minute break must be deducted. This means the available production time is 450 minutes. Additionally, you have calculated that the daily customer demand is 150 products. The formula you will then apply is:
Takt time = available production time / customer demand
Which in this case means:
Takt time = 450 minutes / 150 products = 3 minutes per product
This means that a product must be completed every 3 minutes to meet customer demand. If the actual production time per product is longer than 3 minutes, delays will occur. If it is shorter, there may be overcapacity or waste.
How can you use the calculated takt time?
Calculating takt time helps optimize your production processes. It allows you to perfectly align production capacity with customer demand. This process alignment ensures that each production step follows the required pace to prevent shortages and overproduction. At the same time, it makes it easier to properly plan personnel and necessary resources, optimizing your inventory management and cost control. Additionally, you can identify bottlenecks in production and improve workflow efficiency.
How do takt time, cycle time, and lead time relate to each other?
Takt time, cycle time, and lead time are closely connected and impact each other. Aligning all three metrics ensures a smooth and customer-focused production process. Takt time determines the production rate needed to meet demand. Cycle time shows the actual time needed to produce one unit. Cycle time should always be equal to or shorter than takt time to prevent backlogs. Lead time includes waiting times and transportation, which influence and are influenced by cycle time. A high cycle time can unnecessarily extend lead time. By carefully monitoring these three metrics, you can enhance overall efficiency and ensure on-time delivery.
Questions about takt time in your production process? Contact us!
Would you like to better manage takt time and other key production metrics within your organization? At EZ Factory, we are happy to help! With our digital platform, accessible throughout the factory, you can quickly detect deviations in production times and ensure targets are met. Clear work instructions are always at hand, allowing employees to follow processes quickly and accurately. Looking to improve efficiency and process standardization? Contact us!