- 10 Common Misconceptions About Lean Manufacturing
- Ten Reasons Why One Piece Flow Will Not Work
- The Best Visual Control in the World
- Give Me 60 Minutes and I'll Give You a Lean Transformation
- Toyota Owes Grandpa Ford
- Look Up from Your Work and Ask: ;Could We Flow This?
- Ouch! Change Hurts
- E-mail 5S
- The Top 5 Reasons for Using Production Preparation Process (3P)
- You've Gotta Go to Gemba More Often Than That!
- 5S Your Desk: And Other Tips for Office Productivity
- Skill Matrix Enables Suggestion System
- Work Content for Line Leads
- Strong Supervision: The Key to Long-term Kaizen
- The Four Elements for Sustaining Kaizen
- Keys to Sustaining 5S
- Top 10 Improvement Tools Named After Lean Sensei
- Intuition, Information and the Toyota Production System
- Nine Rules for Fighting Endless Meetings
- Lean Companies
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- Got Boondoggle?
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101 Kaizen Templates: Takt Time CalculatorA reader pointed out that the takt time for posting the 101 kaizen template has exceeded. It is true that we have not been hitting a consistent 1 template per 3.5 days. To meet our goal for 101 of these by the end of 2008 we will need to recalculate our takt time. Conveniently, we have a takt time calculator as a template for this. There are two sections to this kaizen template in order to make it easy to show two possible takt time scenarios. There may be an average takt time and a takt time during peak volumes. This information is useful in designing production lines or equipment so that the maximum capacity as well as the daily average can be taken into consideration. This takt time calculator will calculate takt time for you under a variety of conditions such as break times, number of working shifts, shift structures and working hours per shift. Fill in the white cells. The blue cells will calculate automatically. The sheet is protected so that you don't accidentally delete the formulas. It is not password protected so feel free to select Tool / Protection / Unprotect Sheet if you would like to modify this template. Back to the issue of non-performance to takt time on this blog. What is the kaizen action to be taken? Of course root cause analysis and corrective action must follow, but an immediate recovery plan is necessary in the mean time. For illustrative purposes the takt time calculator was modified to show the original plan of one kaizen template every 3.5 days, not adjusted to one every 2.1 days based on the remaining number of kaizen templates (95) the remaining number of blogging months (11) in 2008 and a more realistic number of "available days" per month for blogging (20). By Jon Miller - February 4, 2008 11:41 PM 
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Comments
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Dear Jon Oops. Thanks Chris. You are right. 95 left to go, not 101. Hi Jon this is a really useful and great template, it's going to be really useful to me, i just have one question/slash observation, Planned downtime cells (C10 and C25) are not referenced in any other cell, so either is information we are not going to need/use (waste) or it should be referenced to Net Working time cells (C11 and C26) please clear this out for me. thanks. Thanks for the observation Alberto. The template has been corrected and uploaded again. The C10 and C25 cells are indeed relevant now they are referenced as part of the calculation correctly. That should be a good reminder to everyone to check your their work for errors after modifying this template and before distributing it. I have question, I know how to calculate tt, my problem is a I have a production line that has 3 product families produced. Product 1 volume 356/day sum of cycles 80 sec, Product 2 volume is 103/day sum of cycles 200 sec and Product 3 volume is 89/day sum of cycles 152. How do I give each product family a TT.? Staffing is 3, 25800 sec. Available Time If you have 3 product families you need to calculate 3 takt times. Staffing is irrelevant. I wouldn't recommend running a mixed model line unless the downstream customer needs one of each product to make a set or shipment. It is better to run one product family for a few hours until the daily demand is met, then switch to another, etc. in a daily pattern. Roughly speaking you will need 2,8480 sec (80 x 356) for Product 1, 20,600 sec (103 x 200) for Product 2 and 13,528 (89 x 152) for Product 3. The sum of cycle time (I am assuming you mean manual time) is 62,608 sec so the optimum staffing is 2.4 people. If you have one piece flow and cross trained workers it becomes much easier since you can simply divide the work content for each product by 2 or 3 evenly and run until finished based on not the "true" takt but something called "actual takt". For example if you could balance the workload and pace the flow for Product 2 at 67 seconds per person with 3 workers you could finish your daily requirement in about 3 hours and 20 min. Good luck! |
