How do you measure and improve the performance and efficiency of your Takt time system?

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Takt time is a key concept in lean process improvement, as it defines the rate at which you need to produce to meet customer demand. However, measuring and improving your takt time system is not a one-time activity, but a continuous cycle of monitoring, analyzing, and adjusting. In this article, you will learn how to use an Andon system and other tools to optimize your takt time system and enhance your efficiency and performance.

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Erivelton Texeira

Top 50 Creators Gest?o de Projetos Favikon |LinkedIn Top Voice | Lean Manufacture| Melhoria Continua | Lideran?a

1 What is an Andon system?

An Andon system is a visual and audible signal that alerts operators, managers, and support staff of any problems or deviations in the production process. It helps to identify and resolve issues quickly, prevent defects, and reduce waste. An Andon system can be triggered manually by workers or automatically by sensors or machines. It can also display the status of the production line, such as the current takt time, cycle time, output, and quality.

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Erivelton Texeira

Top 50 Creators Gest?o de Projetos Favikon |LinkedIn Top Voice | Lean Manufacture| Melhoria Continua | Lideran?a
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Ele se refere a um sistema de sinaliza??o visual muito utilizado em ambientes de manufatura, especialmente na filosofia Lean e na produ??o enxuta. A gente pode dizer que a origem do termo vem do japonês, onde "andon" significa "lanterna" ou "luz". E a ideia por trás disso é realmente alertar sobre o status da linha de produ??o. Normalmente, o sistema Andon é representado por luzes coloridas, cada uma indicando um estado diferente. Por exemplo, uma luz verde pode significar que tudo está operando normalmente, enquanto uma luz amarela pode indicar que há um problema e, se a luz ficar vermelha, é hora de chamar por assistência.

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Erivelton Texeira

Top 50 Creators Gest?o de Projetos Favikon |LinkedIn Top Voice | Lean Manufacture| Melhoria Continua | Lideran?a
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Andon significa “lampada” ou “lanterna japonesa”. Na verdade, é uma ferramenta cuja fun??o é fazer a gest?o de resultados, assim como de ocorrências em uma linha de produ??o. A ferramenta Andon ajuda a sinalizar toda a equipe a respeito de possíveis falhas que possam ocorrer num determinado processo produtivo, esses sinais podem ser feitos através de alertas sonoros, sinalizadores visuais (TV ‘s) e demais representa??es visuais.

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Osama Alghamdi

Leader | Director | Inspirational | Lean Maintenance | Maintenance Management Expert | Adaptability | Reliability |Lean Concept | Defense Acquisition | Creativity | Trainer | Writer | Growth Mindset, MSc Engineer @ RSLF
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To measure & enhance the performance & efficiency of your Takt time system, start by establishing KPIs such as cycle time, defects, & commit to a schedule. This will provide valuable insights to the system's effectiveness and to identify areas for improvement. Next, analyze production data, adress bottlenecks & process inefficiencies. Look for patterns or trends that may cause delays or disruptions in workflow. Address issues and streamline operations by Implementing continuous improvement. Regularly monitor progress against established KPIs to track improvements over time. Adjust, align & optimize resource utilization. Invest in training & development programs to equip employees with the skills and knowledge needed to operate efficiently.

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Dr. Khurshid Khan

Lean Management, Productivity and Six Sigma Consultant, Ayurvedic Health Medicine Consultant
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Measure and improve the performance and efficiency of your Takt time system by regularly tracking production output against customer demand to ensure alignment. Analyze bottlenecks and cycle times to identify opportunities for process optimization and waste reduction. Implement visual management techniques to monitor Takt time adherence and provide real-time feedback to operators. Utilize continuous improvement methodologies like Kaizen to streamline workflows and enhance efficiency incrementally. Engage employees in problem-solving and decision-making to foster a culture of ownership and accountability for Takt time performance.

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2 How to measure your takt time system?

To measure your takt time system, you need to collect data on your customer demand and your available production time. Customer demand is the average number of units that your customers order in a given period, such as a day, a week, or a month. Available production time is the total time that your production line can operate in the same period, minus any planned or unplanned downtime, such as breaks, maintenance, or changeovers. You can calculate your takt time by dividing your available production time by your customer demand. For example, if your customers order 1,000 units per day, and your production line can operate for 8 hours or 480 minutes per day, minus 60 minutes of downtime, your takt time is 0.42 minutes or 25 seconds per unit.

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Singh Yuvraj

Experienced Logistics & Supply Chain Professional | 13+ Years in Transportation, Warehousing, and In-Plant Operations | Skilled in 5S & Kaizen Methodologies for Continuous Improvement
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Measuring and Improving Takt Time ??????: Measure (????): Calculate and monitor actual Takt time. Analyze (????): Identify bottlenecks and inefficiencies. Optimize (????): Streamline processes and resources. Iterate (????): Continuously refine to match demand.

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3 How to improve your takt time system?

To improve your takt time system, you need to compare your actual cycle time with your takt time, and identify and eliminate any sources of variation or waste. Cycle time is the actual time that it takes to produce one unit of output, from start to finish. Variation is the difference between the shortest and the longest cycle time for the same product or process. Waste is any activity that does not add value to the customer or the product, such as defects, overproduction, waiting, inventory, motion, transportation, or overprocessing. You can use tools such as value stream mapping, 5S, standard work, kaizen, kanban, poka-yoke, and heijunka to streamline your process, reduce variation and waste, and balance your workload and capacity.

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Rodrigo álvares

Engenheiro de Produ??o I Processos I Qualidade I Planejamento I Opera??es I Melhoria Contínua I Excelência Operacional
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A principal ideia por trás do takt time é sincronizar a produ??o com a demanda do cliente, evitando tanto a superprodu??o quanto a subprodu??o. Quando o takt time é respeitado, a produ??o ocorre de forma constante e eficiente, garantindo que os produtos sejam entregues no ritmo exigido pelo mercado.

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Nimit Bajaj

Helping small and medium size manufacturing businesses improve labor productivity and cashflow | Adding value by solving complex operations problems through Lean and Six Sigma
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Takt time is essentially customer demand and we cannot improve takt time. But on the other hand we can improve cycle times for a process to meet takt time.As a general rule of thumb cycle time should be 85% of takt time to account for machine breakdowns or unpredictable work stoppage. Value stream mapping is the best way to design a process to meet customer demand or takt time.

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4 How to monitor your takt time system?

To monitor your takt time system, you need to track and display key performance indicators (KPIs) that reflect your efficiency and quality. KPIs are measurable and quantifiable metrics that show how well you are meeting your goals and customer expectations. Some examples of KPIs for takt time system are: takt time adherence, which is the percentage of cycles that match or beat the takt time; cycle time variation, which is the standard deviation of the cycle times; first pass yield, which is the percentage of units that pass quality inspection without rework; and overall equipment effectiveness (OEE), which is the product of availability, performance, and quality rates.

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5 How to adjust your takt time system?

To adjust your takt time system, you need to respond to changes in customer demand or production conditions. Customer demand can fluctuate due to seasonality, trends, promotions, or feedback. Production conditions can change due to equipment breakdowns, material shortages, staff turnover, or process improvements. You can use tools such as demand forecasting, pull systems, takt time boards, andon lights, and gemba walks to anticipate and communicate changes, and adjust your takt time accordingly. For example, if your customer demand increases, you can reduce your takt time by increasing your production speed, adding more resources, or reducing non-value-added activities. If your customer demand decreases, you can increase your takt time by reducing your production speed, removing excess resources, or increasing value-added activities.

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How do you measure and improve the performance and efficiency of your Takt time system?

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1 What is an Andon system?

2 How to measure your takt time system?

3 How to improve your takt time system?

4 How to monitor your takt time system?

5 How to adjust your takt time system?

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