CYCLE TIME

Objective

1. To compare with takt time and to determine the optimal number of workers needed to complete an operation or process. 
2. Reduce cycle time and develop standard work.

Operating Procedure

1. Check the details related with product and prepare study plan.

• Detail of the operation.
• Detail of material and accessories
• Detail of machine
• Skill of the operator
• Detail of location and environment 

     2. Prepare the cycle time sheet

    3. Prepare the Timer Clock

There are two types of cycle time:

1. Individual cycle time :The rate of completion of an individual operation ; for example, packing or welding.
2. Total cycle time :The rate of completion of process of operation. You calculate this number by adding together all individual cycle time in given process.

How to check cycle time

1. Start to check individual cycle time  from first process.
2. Start records began moving from the normal position to pick up the pieces to complete one cycle.
3. The number of recording cycle time working depends on the desired resolution. Usually it takes 25 cycles or more to enable such information to be used in the statistical analysis.
4. After completing collecting all the data we could find a number of employees we need in each processes and total cycle time.

EXAMPLE 

Working hour = 8 hours , order = 7,200 units and working day = 10 days

From question 

1. Working hour= 8 hours x 60 minutes x 60 seconds = 288,000 seconds 
2. Order = 7,200 units
3. Working day = 12 days
4. Downtime = 60 minutes per day = 3600 sec. per day

Takt Time =  (288,000 sec. - 3600 sec.) x 12 days / 7,200 units = 42 sec. 

So customer want 1 unit every 42 sec.

Operation Process Control (OPC)

Cycle Time data

The graph shows a comparison between Individual cycle time and Takt time

Next step

• Determining the optimal number of workers is calls line balancing. It is the process by which you evenly distribute the work elements among all operators.
• Process analysis to determine loss and utilize kaizen activity to reduce cycle time and improvement.