Takt time is the cycle time needed in a production system to match the pace of production to the demand rate and is used in Lean Production systems for line balancing. Given the following data, what is the takt time per shift? Total time per shift is 480 minutes. There are two 15 minute breaks and one 30 minute lunch. Daily demand is 160 units.
a. 2.625 minutes per cycle
b. 2.813 minutes per cycle
c. 2.906 minutes per cycle
d. 3.000 minutes per cycle
The correct answer and explanation is:
The correct answer is:
a. 2.625 minutes per cycle
Explanation:
Takt time is a crucial metric in Lean Production systems that helps synchronize production output with customer demand. It ensures that manufacturing operations are balanced and efficient, reducing waste and improving workflow.
Step-by-Step Calculation
- Determine Available Time Per Shift:
- The total working time in a shift is 480 minutes.
- Breaks include:
- Two 15-minute breaks → 15 × 2 = 30 minutes
- One 30-minute lunch break → 30 minutes
- Total break time: 30 + 30 = 60 minutes
- Net available working time:
[
480 – 60 = 420 \text{ minutes}
]
- Determine Daily Demand:
- The company needs to produce 160 units per shift.
- Calculate Takt Time:
- Takt time formula:
[
\text{Takt Time} = \frac{\text{Net Available Time per Shift}}{\text{Daily Demand}}
]
[
\frac{420 \text{ minutes}}{160 \text{ units}} = 2.625 \text{ minutes/unit}
]
Thus, each unit must be completed within 2.625 minutes to meet customer demand.
Importance of Takt Time
- Ensures line balancing, preventing bottlenecks or idle time.
- Helps in capacity planning to determine if current resources meet demand.
- Supports continuous improvement by identifying inefficiencies.
Maintaining a takt time of 2.625 minutes allows the company to deliver on time while optimizing labor and machinery usage. Overproduction or underproduction can be avoided, making production lean and cost-effective.
Now, let’s generate an image illustrating this concept.
Here is an infographic illustrating the concept of Takt Time in lean production. It visually explains the formula, factory workflow, and key calculations related to cycle time and demand. Let me know if you need any modifications or further explanations!
