We Can't Hit Takt Time
Takt is the pace demand sets. Missing it means the line cannot keep up even on a good day. The gap is usually a few stations over takt, or losses that make a station's real cycle longer than its time study.
What Is Usually Going On
- One or more stations carry work content over takt.
- Stops, waiting for parts and rework stretch the real cycle past the planned one.
- Takt was set from gross time, not net available time.
- Work is not standard, so cycle time varies by operator and by unit.
How to Fix It
- Check taktTakt = net available time / demand. Net means breaks, meetings and planned stops are out.
- Time every stationTen or more observed cycles each, with the spread noted.
- Plot against taktA yamazumi chart shows which stations are over, and by how much.
- Plan below taktSet a target cycle below takt to absorb small losses. Size the margin from your own stop data.
- Move or cut workShift work elements from stations over takt to stations under. Remove waste at the heavy station before buying equipment.
- Hold it with standard workWrite the new sequence and train to it, so the cycle stays where you put it.
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Common Questions
What is the difference between takt and cycle time?
Takt is the pace demand sets: available time divided by demand. Cycle time is how long a station actually takes per unit. Cycle time has to be below takt.
Should cycle time equal takt?
No. Plan stations below takt so small stops do not put the line behind. How far below depends on your own losses.
What if the work content does not fit any balance?
Then the line needs another station or person, or less work content. Operators = work content / takt, rounded up.
Can I change takt?
Only by changing available time (shifts, hours) or demand. Changing the line changes cycle time, not takt.