Takt Time: worked example
| Available production time (minutes) | 450 |
|---|---|
| Customer demand (units) | 90 |
| Takt time (minutes per unit) | 5 |
| Takt time (seconds per unit) | 300 |
Takt Time: formula
Common error: Confusing takt time with cycle time. Takt time is set by demand, while cycle time is how long a station really takes, and the two are compared to find the gaps.
Available production time is the time per shift or day in which the line can run, after breaks, meetings and planned maintenance, in minutes. Customer demand is the number of units the customer requires in that period, taken from orders or a demand forecast. Use consistent units.
If demand varies by day or season, calculate takt time for the peak as well as for the average.
Takt Time: changing Available production time (minutes)
| Available production time (minutes) | Takt time (minutes per unit) | Takt time (seconds per unit) |
|---|---|---|
| 360 | 4 | 240 |
| 405 | 4.5 | 270 |
| 450 (example) | 5 | 300 |
| 495 | 5.5 | 330 |
| 540 | 6 | 360 |
Takt Time: compare input ranges
| Input | Tested from | To | Takt time (minutes per unit): low input | Takt time (minutes per unit): high input | Swing |
|---|---|---|---|---|---|
| Available production time (minutes) | 405 | 495 | 4.5 | 5.5 | 1 (20%) |
| Customer demand (units) | 81 | 99 | 5.6 | 4.5 | 1 (20%) |
Takt Time: individual input comparisons
| Input | Value | Takt time (minutes per unit) | Takt time (seconds per unit) |
|---|---|---|---|
| Available production time (minutes) | 360 | 4 | 240 |
| 405 | 4.5 | 270 | |
| 450 | 5 | 300 | |
| 495 | 5.5 | 330 | |
| 540 | 6 | 360 | |
| Customer demand (units) | 72 | 6.3 | 375 |
| 81 | 5.6 | 333.3 | |
| 90 | 5 | 300 | |
| 99 | 4.5 | 272.7 | |
| 108 | 4.2 | 250 |
Takt Time: combined input changes
| Available production time (minutes) / Customer demand (units) | 72 | 90 | 108 |
|---|---|---|---|
| 360 | 5 | 4 | 3.3 |
| 405 | 5.6 | 4.5 | 3.8 |
| 450 | 6.3 | 5 | 4.2 |
| 495 | 6.9 | 5.5 | 4.6 |
| 540 | 7.5 | 6 | 5 |
Takt Time: which assumptions move the result?
Takt Time: values and definitions
| Quantity and definition | Value used |
|---|---|
| Available production time (minutes) — Shift length less breaks and planned stops. | 450 |
| Customer demand (units) — Units needed in that same time. | 90 |
| Takt time (minutes per unit) | 5 |
| Takt time (seconds per unit) | 300 |
Takt Time: half and double Available production time (minutes)
| Available production time (minutes) | Takt time (minutes per unit) |
|---|---|
| 225 | 2.5 |
| 450 | 5 |
| 900 | 10 |
Takt time is driven by demand, not by machine capacity, and it is a target, not a measurement of actual speed. It does not account for downtime, defects or changeovers unless you adjust available time. Frequent changes in demand require recalculating.
Mixed-model lines need a weighted figure.
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Takt time is the pace a production line must hold to meet demand: available time divided by the units the customer needs. A shift with 450 minutes of production and demand for 90 units has a takt time of 5 minutes per unit, or 300 seconds. If a station takes longer than that, it becomes the bottleneck, and a station that is far faster is idle or overproducing.
Use time available for production. Breaks, meetings and planned maintenance come out before you divide.
Compare with the overall equipment effectiveness calculator to see whether the line can hit the pace, and Little's law for the inventory needed in the flow. The safety stock and reorder point pages address materials. Balance the work so each station's cycle time is just under takt.
What is the difference between takt time and cycle time?
Takt time is how often you must produce a unit to meet demand, and cycle time is how long a station takes to produce one. Cycle time must not exceed takt time.
How do I calculate available time?
Subtract breaks, meetings and planned stops from the shift length. Only the time the line can produce counts.
What happens if demand changes?
Takt time changes in inverse proportion, so a 20% rise in demand cuts takt time by about 17%, and you must adjust staffing and stations.