CYCLE TIME

Includes cycle time capturing guidelines, reason for non

adherence of output to defined hourly standard and
solutions, Variations in cycle time study and key things in
cycle time study
 DEFINITION
What is Cycle Time?

The cycle time is the time taken by an average operator, working at normal speed to
produce 1 part in a process using resources required for that part to be produced
OR
The cycle time is the time it takes to complete a task from start to finish for
producing 1 part
OR
an average of the completion times of a repetitive productive process or task i.e.
Total Time Taken divided by parts produced in that time.

 Important point to remember

Cycle time is not throughput time and not even Lead Time. These are
separate things and will be explained in separate article
 COMPONENTS OF CYCLE TIME
What are the components of a Cycle Time?
So a Typical cycle time in a machine shop would comprise of
• Unloading part from machine – Time elapsed from machine stop to remove the
part from machine
• Loading fresh part into machine – Time elapsed from start of loading part to
putting machine in Auto Cycle
• Machine processing time – Machine cycle time
• Cleaning/ inspection time – Time required for inspecting parts
• Part transfer time – Time required for transferring part to next station/ bin
• Wait Time – Waiting time for completion of part / supply from previous station
• Walk Time – Time elapsed in moving from one place to another for completion
of cycle
 CYCLE TIME – EXAMPLE 1
Case 1 – When Operator is operating only 1 machine

Time, In Seconds
Sub Task 3 6 9 12 15 18 21 24 27 30
Unloading part from
machine
Loading fresh part into
3

machine
Machine processing
3

time
Cleaning/ inspection
21

3
time
Part transfer time 3
Wait Time 18
Walk Time

So Cycle time in the example is =

++ = 27 Secs
 CYCLE TIME – EXAMPLE 2
Case 2 – When Operator is operating only 2 machine
Time, In Seconds
Sub Task 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45
Unloading part from machine 1 3
Loading fresh part into machine 1 3

1st Part
Machine processing time – 1 21
Cleaning/ inspection time – 1 3
Part transfer time – 1 3
Walk Time 3
Unloading part from machine 2 3
Loading fresh part into machine 2 3

2nd Part
Machine processing time – 2 21
Cleaning/ inspection time – 2 3
Part transfer time – 2 3
Walk Time – 2 3
Wait Time

So Operator Cycle time in the example is = 30 Secs

So Effective Cycle time in the example is = 30/2 pcs = 15 Secs
Please note – First & last cycle ignored for easy calculation depiction
 METHODS OF CYCLE TIME CALCULATION
What are the different ways of calculating a cycle time?
There are 2 methods deployed by organizations/ individuals for cycle time
calculations for a product.
1) Establishing cycle time for each process (for a product) by use
of stop watch and then picking highest cycle time (also known
as bottleneck). This gives a more accurate throughput time
(covered in separate forth coming article)
2) Establishing cycle time by end of line output monitoring.
In this case what we get is fairly accurate through put time for
the line (if done at the end of line) and fairly accurate cycle time for the process
(if done on each machine)
The first method is more scientific, detail oriented and interactive in nature
as one has to observe gemba which gives more insights into wastes along with
several kaizen ideas whereas in second method waste if any gets added in cycle
time and become part of standard.
CYCLE TIME – BATCH VS DISCRETE PROCESS
What is the difference between cycle time for a batch production Vs cycle time
for discrete process?
Cycle time for discrete process is cycle time for a single product. Example is a
machining on a CNC lathe where one part gets processed in each cycle. Example on
slide 4 represents this kind of cycle time.
Cycle Time = 𝑺𝒆𝒄𝒐𝒏𝒅𝒔Τ𝑷𝒊𝒆𝒄𝒆 = 𝟑𝟓 𝑺𝒆𝒄Τ𝑷𝒊𝒆𝒄𝒆

Cycle time of a batch is different. It is irrespective of the parts going in but it

depends upon process time. So in essence it is process time. It is usually given in
time per a set number of units. Example of this kind is a paint booth process. So if
say in 1 go 10 parts are to be loaded in painting booth, and it takes 5 minutes. if we
load 5 also, the time will more or less same i.e. 5 minutes only. Another common
example is heat treatment, plating processes etc
Cycle Time = 𝑺𝒆𝒄𝒐𝒏𝒅𝒔Τ𝑩𝒂𝒕𝒄𝒉 𝑺𝒊𝒛𝒆 = 𝟑𝟔𝟎𝟎 𝑺𝒆𝒄Τ𝟏𝟎𝟎 𝑷𝒊𝒆𝒄𝒆𝒔
 BIGGEST PROBLEM OF MANUFACTURING
One of the common Problem of manufacturing

HOURLY PRODUCTION RATE NOT MATCHED WITH DEFINED HOURLY

STANDARD

WHY?
It is difficult to match defined cycle time. Probable reasons are
1. Cycle time not defined properly (some of the elements left out)
2. Hugh variation in cycle time even by same person when performing again and
again
3. Real Time Plan Vs Actual not monitered
4. Losses
 DOING CYCLE TIME STUDY
Lets Get into details of how time study should be done. What format should be
used, what details are to be added/ removed and what analysis should be carried
out. Mind you

Doing Cycle Time study is not for sake of putting some numbers, it is actually
setting up a standard, a standard your organisation will be emulating, So it should
be done with utmost care and precision so as to avoid on either side of the
problem (too loose/ too tight standard)

Some of the basic guidleines for doing time study and establishing cycle time is as
follows:
 GUIDELINES FOR TIME STUDY
1. Visit Gemba and understand the contents of the process
2. Differentiate these between regular repeated Vs repeated at certain
frequency.
3. Observe operator for 5~6 cycles to understand pattern and see if it
matches with point no 1.
4. Suggest Immediate kaizens (like bringing material closer, sequencing the part
keeping etc) and implement it.
5. Explain to operator rationale of doing time study and establish , explain
pattern to him before starting
6. Again repeat step 3.
7. Establish “START” and “END” of each sub task. For example you are
monitoring loading and unloading part, so start and end should be naturally
 GUIDELINES FOR TIME STUDY (Contd)
naturally ending thing i.e. when operator touches part for picking should be
start of your cycle time. Like wise when he press start button, it should indicate
end of loading/ unloading cycle. This eliminates any cycle to cycle variation
generated while doing time study
8. Place yourself at such a place that all content are easily watchable when
operator is working. You should not move for capturing the content.
9. Operator should not be too new, should be neither too fast, nor too slow
10. Minimum 20 ~ 30 cycles are must for establishing the cycle time
11.All process related parameters should be captured and documented. This
is critical because with change of parameters, cycle time may ( and will)
change. This is yet another reason for variation in cycle time
12. Capturing through Video definitely have edge over traditional method.
 OPERATOR TIME ANALYSIS SHEET
This format is used for operator time analysis and there are few very important
things one has to understand:
①
⑥

⑤
 OPERATOR TIME ANALYSIS SHEET (Contd)
① All the information pertaining to line, operator etc. is very critical to capture.
Most important is operator details including his experience on this process as
well as his speed rating. This Speed rating evaluation comes with experience and
varies with the observant.
② All the task should be broken into sub elements which should be natural
ending i.e. there should be only one time when the element is said to start say by
touching machine start button, by touching part for picking it for loading.
Important here is that it should not be broken into too frivolous elements which
becomes difficult to observe.
③ After all the repetitive elements are captured, those elements (like bringing
bin on line, tool change etc.) which are done at certain frequency to be listed. Both
time as well frequency to be added. In the example picture, tool changing is done
after 1000 Pcs and it takes 5 mins (300 seconds). So this time should be accounted
for each cycle i.e. 300/1000 = 0.3 Sec to be added in cycle time.
 OPERATOR TIME ANALYSIS SHEET (Contd)
This is one of the key reason for hourly production rate not matched with
defined hourly standard (see Slide 8)
④ While doing time study, sometimes time taken by operator is abnormal (high
or low) due to any reason, then it should be marked with  omitted. If any
element is missed by the operator while doing repetitive cycles, it should be
marked with ● and omitted. Similarly sometimes , capturing of time is missed by
the observant, then this should be marked with “m”
⑤ These additional details are required in order to understand process settings
at the time of doing cycle time study. In certain cases, changes in these results into
change in cycle time. So this should be part of details while defining the standard.
So This is also one of the key reason for hourly production rate not matched
with defined hourly standard (see Slide 8)
⑥ Most important activity is analysis of the cycle time study just done. It holds
the key for Hugh variation in cycle time.
 OPERATOR TIME ANALYSIS SHEET (Contd)

So the total cycle time variation recorded is +20%/ -8% which is hugh. Max to Max
variation should be +/- 3~5%. Anything beyond suggests that operations is not
stable and repeatability within time is highly doubtful.
So on deep diving for each work element, Open machine and unload part is
having the maximum variation +24%/-19%. So it indicates that even the cycle time
of 2.6 is on the higher side and can be optimized once cycle becomes stable and
repetitive. For this to achieve, one must focus on reason for variation and kaizens
should be planned for the same.
 SOLUTIONS TO CYCLE TIME VARIATIONS
For Example, pnematic cylinders can be attached to machine doors for automatic
opening of doors when cycle gets completed;
Another can be auto unloading using automation or even use of gravity if part is
not prone for any damage
Another can be carefully examining and documenting “HOW” of loading method
adopted by operator. This can be used to train others using JI method.
Another idea can be use of auto loading/ unloading mechanism.

The List can be unending and depends upon issue and exploring non expensive
ways to achieve this goal. But this is one of the most ignored reason for Hugh
variation in cycle time even by same person when performing again and again
resulting into HOURLY PRODUCTION RATE NOT MATCHED WITH DEFINED
HOURLY STANDARD
 USE OF TECHNOLOGY
Technology can be used to do time study. Stop watch and Video cameras are very
commonly used equipments. Now a days there comes varying levels of solutions
that aid cycle time capturing to a great extent. These are:
1. Macro enable excel worksheet – in this, you need to breakup element and once
that element starts, you need to press start and once it ends press end, all
calculations will be done automatically. This is to be repeated for each
element. One such worksheet is available on econoshift.com developed by
Masashi "Mike" Negami.
2. Another is use of software that uses video. You press button to mark and end
of element on video itself, it makes all the calculations and reports associated
with it can be published. One can visit apparelresources for some of these
listings over there.