After gaining an in-depth understanding of how takt time, line balance, and flow works, what their various calculations are etc., I’m sure you’ve got questions! I’ve collated some of the most frequently asked questions that I’ve come across regarding these Lean tools. Check them out:
1. I am a process executive who wants to apply takt time. I carry out just a small part of the whole work in a throughput process. How do I apply takt time to my work area?
– Think of your next step to be your customer. How many completed work units does it need from you? Hence, consider this as your demand. Accordingly, carry out takt time calculations. Now let’s assume you need to finish all that comes your way during the day, and then send it to your next step. In this case, the number of work units you receive during the day (consider an average) itself becomes your demand.
2. While considering ‘flow and balance’, what if there is more than one process step whose cycle time is greater than the takt time?
– The step with the highest cycle time is the bottleneck. However, if there is a tie, both become bottlenecks.
3. Let us say I’ve got many steps where the cycle time is greater than the takt time. Should I aim to reduce the cycle time for all the steps at once?
– It depends. If you have the time and resources to do so, then go for it! However, if you don’t, then prioritize and act. Additionally, you may need others, or a cross-functional team, to engage!
4. My cycle time at a step runs into ‘days’. Does it still work?
– It does! Make sure you mention the number of days it takes at each step as your cycle time. Furthermore, identify the step that takes the most days which exceed the takt time. Then break it down further, set your priorities, and act accordingly.
5. Does takt time still apply to us if we only carry out one project per 3 months?
– It does! However, calculations are different and customized. For instance, let’s say that within a project you release 100 work orders to suppliers during the first stage while ordering. As a result, a takt time applies as one work order to the supplier every ‘n’ number of days or hours. Hence, you need to customize the idea that is best suited for your domain. Ensure it makes sense for your business and industry.
6. Is it enough if the only person that understands the concept of takt time and aligns themselves to achieve the ‘end customer’ demand is me?
– Everyone needs to understand the concept of takt time, line balance, and flow. It is the key to making the entire operation a success. Therefore, while you can try to be the only person that looks into it, remember that it might not be successful.