Cycle time

Awareness, Optimizing, Benefits

CYCLE TIME
● Any frequently repetitive activity that adds value to product/process is
called cycle.
● The frequency may vary depends on its need and time.
● Generally it is believed only production department is mainly concerned
with cycle time, which is very much wrong.
● Inspection, First piece approval, calibrating a gauge, validation of special
fixture/tools all activities cycle time to be monitored.
● Reduction of cycle time is achieved by reducing/eliminating NVA.
Cycle time, takt time, lead
time.
● Cycle time –start- repetitive chain of activities-End-Restart

● Set of actions resulting in process transformation as per design(customer or next

process) requirement leading to value addition Is a cycle. Time taken for
completing a cycle is called cycle time..

● Examples

● Machining, cleaning, deburring, inspection,

● Blood sample collection, BP checking,
● Loading of goods to truck
● Un packing, Packing,
LEAD TIME
CYCLE TIME –DEFINITION,
CALCULATION
● Time taken to complete a process qualitatively, with statutory &safety
regulations as per design or customer(internal/external) requirement
leading to a transformation/value addition.

● Usually calculated with stop watch.

● Start to end time is clocked

● Theoretically also calculated, But stop watch time study is best

Ideal and average cycle time
● Ideal cycle time is the best and minimum possible time with best
performances . It is a Master time to be compared with current or actual
time.

● Average cycle time is the average calculated after a study of same

process but many times to find the best standard time.
How to improve cycle time
● Identify 3M—MUDA(SEVEN WASTES, MURI,MURA)
● Prioritise,Analyze and find the root causes
● Perform the counter measure with out affecting PQCDSM.
● Implement, Monitor, and standardize
● Re check for the sustenance of the improvement
● Horizontal deployment so that the improvement becomes rapid

● YAMAZUMI is another method to reduce cycle time.

Activities –VA,NVA,NNVA
● VA- Customer pays us for this only.
● Example-Physical ,technical change or transformation. Like-machining, heat
treatment, assembly, casting, forging.
● NVA-customer does not pay for this as no such changes and it reflects our
internal in efficiency, lesser capability.
● Examples-Inspection, Rework, Re adjustment, Packing, un packing,
● Muda,muri,mura
● Observation, watching, repeating the same, re counting, cleaning,
Necessary non value added activities
● These are the activities really required for satisfying customer but the time
taken should be kept minimum most possible.

● Examples

● Setting change over, First Off inspection, PDI, Tool change over,
● Preventive maintenance, statutory audits, Gauges calibration.
Minimizing NVAs & Optimizing VAAs
● Minimize or eliminate NVAs by- SCARE(Simplify, combine, adjust, reduce
or eliminate).

● Examples-combination of tools, reducing bolts, dowel pins for location,

setting blocks, eliminating operation by kaizen.

● Optimization- better tool life saves frequent tool changes, better tooling
gives higher feed rates, standardizing reduces time to change, better
spares increases service life, better design changes reduces time to do
preventive maintenance.
● Creative thinking with kaizen approach.
BENEFITS OF CALCULATING CT, LT,
TAKT TIME
● SHOWS THE CURRENT CONDITION AGAINST CUSTOMER REQUIREMENT AND
SETS THE PACE TO IMPROVEMENT

● TRIGGERS THE IMPROVEMENTS TOWARDS MEETING CUTOMER DEMAND

● RESULTS IN AVOIDING SURPRISES,SHORTAGES,PRMEIUM FREIGHTS,
● ABLE TO FORM KPI AND RESULTS IN VALIDATION OF PERFORMANCES
● MOTIVATES AND IMPROVES EFFICIENCY,SKILL SETS,MORALE
● EASY TO IDENTIFY TEAMS FOR REWARDS AND RECOGNITIONS
 EXAMPL
BEFORE AFTER RESULT ACTIVITY

PCD inserts replaced with

E
1(machining-technology ) Face milling ct 2.5 mts Reduced to 1.5 mts Saving 1 mt
carbide

Burnishing drill used.

20 dia boring ct 3.5 mts. 3
2(tooling improvement) Reduced to 2 mts Saved 1.5 Eliminated 2 tools
tools used

Combination drill introduced.

3(tool design improvement) Dia 47 bore ct 4 mts Reduced to 2 mts Saved 2 mts Eliminated chamfering and
fine boring

Master base with dowels

4(SMED) Setting change 35 mts Reduced to 15 mts Saved 20mts
introduced

Jaw boring and setting time SMED jaw introduced. Only

5(SMED) Reduced to 8 mts Saved 17 mts
25 mts jaw clamping. No boring

Tools setting and changing Tools were pre set and

6(kaizen) Reduced to zero Saved 20 mts
time 20 mts changed in lunch time

Introduced taper roller

7(tooling improvement) Taper reaming 15 mts Reduced to 11 mts Saved 4 mts burnishing. Finish reaming
feed increased 50%

On line cleaning with

Machine cleaning time 14
8(kaizen) Reduced to 3 mts Saved by 11 mts customized piping and motor
mts
connection, pump
Design modified for tank and
Suction filter cleaning time
9(PM time reduction) Reduced by 6 mts Saved by 13 mts filter mounting with quick
18 mts
removal
This Photo by Unknown Author is licensed under CC BY-SA