Lean toolkit / 11
Takt and Line Balance
Takt comes from the customer, not from the equipment. Set the drumbeat, load the line against it, and see immediately whether the work is stacked unevenly or simply too heavy.
Balance to takt minus a small buffer, never to the fastest operator. Time the job at the process, ten cycles, and use the lowest repeatable time.
If required operators comes out at 4.3, you have a 4.3-operator problem. Solve it with work content, not by rounding.
1 Available time
Per dayAvailable time—min / day
Takt time—sec / pc
Planning takt—95% — balance to this
Result
How the line sits
Bottleneck—seconds
Operators needed—work content ÷ takt
Operators assigned—from the table
Balance efficiency—85% or better
Balance loss—sec / cycle
Output at bottleneck—pcs / day
2 Station loading
One row per station| # | Station or operator | Work content (s) | Operators | % of takt | vs takt (s) | Balance action | |
|---|---|---|---|---|---|---|---|
| Total work content | 0.0 | 0 | |||||
Yamazumi — work content by station
Under takt
Over takt
Takt line
Takt and Line Balance · DF Consulting · df-consulting.net · david@df-consulting.net