Soft Lines Rapid TAT

VelocityPlay
Playbook

1 1/21/22
 TAKT Analysis –

TAKT Time = Available Time divided by Demand

Available Time in 8 Hour Shift = 480 Minutes

1 Shift
15 Minutes (Morning Break)
15 Minutes (Afternoon Break)
30 Minutes (Lunch)
15 Minutes (Daily Meeting, 6S/Clean Up)

Per Day = 405 Available Minutes

Customer Demand =80 pieces/week

= 16 pieces per day

TAKT TIME = 405 Available Minutes Ʃ Touch Time = 747 = 29 Operators

16 Piece TAKT Time 25
TAKT Time = 25 Minutes per piece

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 WIP Map
Little’s Law (l = λ*w)
WIP = Demand x Time
= (1x25) = 25

Actual WIP =

* Consider Insert here for area layout diagram *

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 Work Stream Terminology
Play book – a document describing how the team members move to support
work cell.
Example: What specific actions need to take place if another team
member is absent
Example: What actions should be taken if the inventory in front of the
pacesetter drops to a minimum level
Example: What action do operators take when they meet their daily output
requirements

Inventory Profile Analysis – Technique to analyze finished goods inventory,

customer service levels and calculate WIP inventory requirements.

Customer Service Level – Expectations of the customer to support their

account to prevent missed deliveries.

Service Level Agreement – Agreement with supporting service centers or

feeder cells to support production work cell.

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Work Stream Terminology
Material Presentation
POU – Point of Use, located where the operator needs it
Supermarket – The location where predetermined standard inventory is kept to
supply downstream processes
Material Handler – Moving necessary material and Kanban cards to its proper
location within the process flow

Single Point Scheduling – Visual display of throughput based on planned throughput at

the pacesetter or other critical process in the work cell.

Bottleneck – The slowest operation (choke point) in a manufacturing process.

Constraint – Often referred as the bottleneck; it is anything that prevents the work cell
from making its goal. Constraints should be exploited to improve throughput.

Safety Buffer – is the level of inventory needed to maintain consistent production.

 Work Stream Terminology
Pace Setter – Generally the process that adds the most value closest to the
finished product.

Safety Buffer – Inventory in place to protect the

pacesetter or other processes in the system.

Ways to manage the buffer

• FIFO – First In, First Out

• Kanban – 2 bin system, for instance

• Batch – printing a group of IDs, for instance

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 Work Stream Terminology
Process Time – Amount of touch time to perform the process or build a product (i.e.
router hours/bid hours)

Lead Time – Amount of time for product to physically move through a process or work
cell to be placed into finished goods (i.e. work order start date to product in FG)

TAKT Time
TAKT = Effective working time per shift
Customer requirement per shift

Examples of takt time (for a 20-day month):

20 units/month = 1 unit/day
30 units/month = 1.5 units/day
480 units/month = 24 units/day = 3 units/hr.

Activity Ratio
Activity Ratio = Router Hours
LT (days) * 24

% Complete and Accurate – The percent of time to which work from an upstream
process is determined by the downstream process to be error free

1/21/22
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 TAT TEAM

RUN RULES
Populate LP#8 first then LP#7, LP#6…to minimum level as a priority
Each landing pad must be handled FIFO due to priority and expedite turn around
need.
All WIP must be kept in assigned location at all times
• WIP locations must be identified.
Production operators cannot work on non-Priority expedite items that would
interrupt daily flow until all in-process is current or ahead of demand.

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 TAT TEAM

Feeder processes i.e. Log- In and Photo need to

provide a steady stream of product flow to the team.

Example: if daily goal is 50 units to send to measure

the team will need enough units upstream to cover the
landing pad at OP 1 (qty 50+) above to create flow
through the area.

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 Planned WIP levels by location

Planned buffer stock levels at landing pads #1 through #5 need to be at

___units to keep samples flowing at a steady pace.

Example : Landing Pad WIP

Chart Rev B 11/18/2021
Demand = 16 Samples/day
Max Level 40 40 40 40 40 32 32 32      
Min Level 20 20 20 20 20 16 16 16      
LP # LP#1 LP#2 LP#3 LP#4 LP#5 LP#6 LP#7 LP#8    

Description
of process
Date steps
10/27/2021 0 0 1 1 0 1 0 1      
10/28/2021 0 0 0 0 4 1 0 0      
10/29/2021 0 0 9 4 1 4 1 2      
11/2/2021 12 4 0 1 0 0 0 16      
11/3/2021 12 15 40 0 2 5 1 3      
11/4/2021 18 41 12 4 7 8 1 2 50 16  
11/5/2021 12 61 16 9 4 7 2 8 48 16  
11/6/2021 12 37 25 15 5 16 3 1 51 18 25

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 Cross Training Matrix – Example for Cross training
MESA/ ASPS / Cross Training Metric

Name / Task

Lead - Cell Leader Rocky Middleton Expert

Eva Gibson Competent

Shaina Pfeiffer Beginner

Kalanda Griesenauer Used to know it

Fernadez Clemons Not Trained

Amy O'Brian Learning Target

Kristina Westlin

Alexis Easterling

Dixie Whittle

Emma Thomas

Nicol Ramirez

Loren Mars

Tammy McClendon

Charles Rowland

Colton Prouty

Joey Johnson

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 Operation Steps 1-2-3-4 Playbook

1. Meet your daily throughput requirement

2. Assist remaining work stations to meet their daily requirement
3. Assist or cross train in the following order:

a. Check daily status to determine where help is needed- If you are qualified to perform that operation
steps task then help that area meet the daily goal to keep the product flowing forward.
b. See Lead/ supervisor for additional assignments
4.When/If downstream of the pace setter operations are meeting their throughput
requirements, evaluate the need to support/cross train operations inside the cell or
feeder processes as necessary.

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 TAT Playbook
1. Meet your daily throughput requirement for testing
a. Testing and verification of programming
b.
c.
2. Assist operations with other tasks as needed to meet demand.

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