Tact Time

TPS Group
Toyota Kirloskar Motor Pvt Ltd

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JIT APPROACH

What is required ?
Produce
Determines the
& When it is required ?
Customer Demand
Convey What Qty. is required ?

How to meet the customer demand ?

Produce as per customer demand.

Manufacturing speed = Selling speed

(Customer Demand)
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 How to Match Manufacturing & Selling speed
Example
Orders from Customers
6,660 Parts a month

Production quantity per month (plan)

6,660
6,660 Parts
Parts aa month
month

Production quantity per day

333 Parts a day

How many seconds per Part Selling speed = Manufacturing speed

do we need?
1 part in every 81 sec.
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Tact Time
How to produce 1 Part in 81 secs.
Getting 1 part in 81 secs.

RM FG

• Ensure all process should produce within 81 secs.

• Set workload to each process equivalent to Tact time.( i.e 81 secs )

Each process produces a part in 81 secs.

&
Product out put will also be in 81 secs.
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Difference between Conventional Approach & Tact Time

Conventional Approach
250

200

150
Tact Time Approach
100

50

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
120

100
80

60
40

20

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Prod
Prod
Total Daily operation time
TACT TIME =
- is Abnormality
Total Daily production requirement

• Output is not consistent & not to the • Consistent output matching Customer
requirement of the Customer demand. demand.
• Each process is set according to work at • Each process is set to produce within the
each station. Tact time.
5 work load is not balanced through out the line)
(Total • Uniform utilization of Resources.
 What is Tact Time ?

• TACT TIME is a time value in which a single part or set

of parts of a unit product is produced.

• It is the maximum time allowed to produce a product in

order to meet demand

• It is decided on the basis of monthly production

requirements ( By customer ) & the amount of operating
time during the month.

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 Takt Time Calculation

Operating Time/Day(regular working hours)

Takt Time ＝
Amount of Production Requirement/Day

Total available Working time = Net Operating time

1st Shift 2nd Shift Total Working time
= (a+b+c+d) +
190 mins. 185 mins. 190 mins. 185 mins. 190 mins. 185 mins. 190 mins. 185 mins.
(a+b+c+d)
a b c d a b c d
= 750 mins/day

6250
Required monthly
production quantity 250
Required Quantity per day
= Number of operating = units/day
days in month
25

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 Takt Time Calculation

750 x 60 =45000″
Operating Time/day (regular working hours)
Takt Time ＝ = 180″
Amount of Production Requirement/day
250 units

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 How to Set Tact Time at Actual Line

If A Product is required 250nos then TT is180 secs.

If the Line runs continously then parts produced will be
250 nos. = Customer requirement

NO LINE STOP is IDEAL CONDITION

a Tea Break b Lunch Break c Tea Break d

TARGET CANNOT BE ACHIEVED
In actual condition there may be problems leading to line stops.
If Line stop of 1800 (30min) secs. Then what will be the production

a Tea Break b Lunch Break c Tea Break d

The line produces only 240 nos

But Customer requirement is 250 nos/day
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 How to Set Tact Time at Actual Line

We need to consider the line capability while

calculating Tact time

One of the method is By Analyzing past efficiency data

The average efficiency we can consider while setting
Tact time
Efficiency Trend
99 98 98 99
97 96 96 97
100
95
90
85
80
75
70
65
60
1 2 3 5 6 8 9 10 12 13 16 17 19 20 23 24 25 27 28 30

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 For example If the line average efficiency is 95% that means 5% of time
is line stop the current conditions. To achieve production with regular
working time we need consider Efficiency to caluclate the TT that is
called Actual Tact time

750 x 60 =45000″X 95%

Operating Time/Shift (regular working hours)
Actual = 171 Sec
Amount of Production Requirement/Shift
Takt Time ＝
250 units

How ever we need to focus towards how to improve efficiency , we

must have targets to improve efficiency and to go to ideal condition

To set actual Tact time usually shop manager has to take decision
consensus with the top management

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 Calculate the Tact Time And Actual tact time for below example
Working time per shift : 450mins, No of shifts: 2
Avg efficiency: Main line 95%, Sub Line 90%

Required Products
Takt Time:108 secs. 500 / Day
SUB LINE Takt Time:108 secs.
Actual Takt Time : 97.2 secs.
Actual Takt Time : 102.6 secs.

MAIN LINE

Takt Time:67.5 secs. Required Products

SUB LINE
Actual Takt Time : 60.8 secs. Takt Time : 180 secs. 300 / Day

Actual Takt Time : 171 secs.

MAIN LINE

To achieve the Tact time

12 The Cycle time must be less then or equal to Tact time.
 Cycle Time
• It is the actual time taken to complete all the Work
elements of a particular process.
• It consists of the manual and automatic feed times.
Process : 1 Process : 2 Process : 3 Process : 4

2 3 2 3 3 3 4
4
4 2 2 FG
RM 1 1 5 5
4 1 1
RM 5 RM RM RM 6
6 5 6 FG
FG FG FG

• To ensure a product at the defined tact time we need to set

the Cycle time of all the process within the tact time.
100
90
80
70
60
Mins.

50
40
30
20
10
0
1 2 3 4 5 6 7 8 9 10 11 12
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Process