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Takt Time Calculation Sheet
Time Observation Sheet
Cycle Time / Takt Time Bar Chart
Part Process Capacity Sheet
Standard Operations: Operator Routine Sheet
Concentration / Spaghetti Diagrams
Takt Time Calculation Sheet
Time Observation Sheet
Cycle Time / Takt Time Bar Chart
Part Process Capacity Sheet
Standard Operations: Operator Routine Sheet
Concentration / Spaghetti Diagrams
Takt Time Calculation SheetTakt Time Calculation Sheet
s Takt Time is the rate at which the customer buys the product.
s Information needed for calculation:s Part numbers Total Operating Time (ie. 8 hours)s Number of breaks and durations Any other additional non-working time during a shifts Monthly production requirementss Number of working days in a month
s Takt Time is the rate at which the customer buys the product.
s Information needed for calculation:s Part numbers Total Operating Time (ie. 8 hours)s Number of breaks and durations Any other additional non-working time during a shifts Monthly production requirementss Number of working days in a month
OperatingTime
Part No. _____________
Number ofShifts per Day Daily Operating Time (A)
min per shift X shift X 60 sec = sec per day
min per shift X shift X 60 sec = sec per day
min per shift X shift X 60 sec = sec per day
1
2
3
MonthlyRequirements perProduction Plan
Number of WorkingDays in the Month Daily Requirement (B)
=Units / Days Units per day
Number ofShifts per day TAKT TIME
Daily Operating Time (A)Daily Requirement (B) = = sec per unit
Daily Requirement (B) = = sec per unitDaily Operating Time (A)
Daily Requirement (B) = = sec per unitDaily Operating Time (A)
1
2
3
Takt Time Calculation SheetTakt Time Calculation Sheet
Information for ExampleTakt Time Calculation SheetInformation for ExampleTakt Time Calculation Sheet
s Information needed for calculation:s Part Number - XM-35s Total available time per shift - 8 hourss 30 minute lunch break, two 10 minute
breakss 10 minutes allotted for clean ups Monthly Requirement - 14,000 unitss Number of days in the month – 20s Number of shifts per day - 1
s Information needed for calculation:s Part Number - XM-35s Total available time per shift - 8 hourss 30 minute lunch break, two 10 minute
breakss 10 minutes allotted for clean ups Monthly Requirement - 14,000 unitss Number of days in the month – 20s Number of shifts per day - 1
Example: Takt Time Calculation SheetExample: Takt Time Calculation Sheet
Part No. __XM-35___
OperatingTime
Number ofShifts per Day Daily Operating Time (A)
min per shift X shift X 60 sec = sec per day
min per shift X shift X 60 sec = sec per day
min per shift X shift X 60 sec = sec per day
1
2
3
MonthlyRequirements perProduction Plan
Number of WorkingDays in the Month Daily Requirement (B)
=Units / Days Units per day
Number ofShifts per day TAKT TIME
Daily Operating Time (A)Daily Requirement (B) = = sec per unit
Daily Requirement (B) = = sec per unitDaily Operating Time (A)
Daily Requirement (B) = = sec per unitDaily Operating Time (A)
1
2
3
14,000 20 700
420 25,200
25,200
70036
Procedure: Takt Time Calculation SheetProcedure: Takt Time Calculation Sheet
1. Part No. -Record the appropriate part number that is being used for the calculation.
2. Operating Time - The number of hours in a shift times 60 minutes equals the total available operating time. Minus any breaks or cleanup time or any other activities that take place daily. This number equals the Operating Time. (Do not take out setup time )
3. Daily Operating Time - The daily operating time is the time available to work in seconds per the number of shifts available to work.
4. Monthly Requirements per Production Plan - This number should be provided to you by scheduling, sales or forecasting to give you an accurate number. Be sure to look at 12 months to understand seasonality.
1. Part No. -Record the appropriate part number that is being used for the calculation.
2. Operating Time - The number of hours in a shift times 60 minutes equals the total available operating time. Minus any breaks or cleanup time or any other activities that take place daily. This number equals the Operating Time. (Do not take out setup time )
3. Daily Operating Time - The daily operating time is the time available to work in seconds per the number of shifts available to work.
4. Monthly Requirements per Production Plan - This number should be provided to you by scheduling, sales or forecasting to give you an accurate number. Be sure to look at 12 months to understand seasonality.
Procedure: Takt Time Calculation Sheet (Continued)Procedure: Takt Time Calculation Sheet (Continued)
5. Number of Working Days in a Month - This is the number of days available to work in a month. Obtain this number from accounting. Make sure to get number of days for all 12 months to be able to calculate takt time for 12 months.
6. Daily Requirement - Monthly Requirements divided by Number of working days equals the daily requirement.
7. Takt Time Calculation - Takt time is calculated by number of shifts available. Daily Operating time divided by daily requirement equals takt time. Calculate takt time for the number of shifts available.
5. Number of Working Days in a Month - This is the number of days available to work in a month. Obtain this number from accounting. Make sure to get number of days for all 12 months to be able to calculate takt time for 12 months.
6. Daily Requirement - Monthly Requirements divided by Number of working days equals the daily requirement.
7. Takt Time Calculation - Takt time is calculated by number of shifts available. Daily Operating time divided by daily requirement equals takt time. Calculate takt time for the number of shifts available.
Time Observation Sheet
Time Observation SheetTime Observation Sheet
s Tool used to capture process / operations and break into small elements.
s Establish “Most Repeatable” time per element to determine baseline measurement for performance.
s Establish “Best Repeatable” time per element to determine new target for performance.
s Tool used to capture process / operations and break into small elements.
s Establish “Most Repeatable” time per element to determine baseline measurement for performance.
s Establish “Best Repeatable” time per element to determine new target for performance.
Time Observation SheetTime Observation SheetPROCESS NAME PART No.
OPERATOR CYCLE TIME o DATE OBSERVER
MACHINE: __________________CYCLE TIME o OBSERVED CYCLES
ORDER OF OPERATION / ELEMENT OPERATION / ELEMENT DESCRIPTION 1 2 3 4 5 6 7 8 9 10 11 12
Most Repeatable Operation/
Element Time
Best Repeatable Operation/
Element Time REMARKSCLOCK
RUNNING TIME
ELAPSED TIME
CLOCK RUNNING
TIME
ELAPSED TIME
CLOCK RUNNING
TIME
ELAPSED TIME
CLOCK RUNNING
TIME
ELAPSED TIME
CLOCK RUNNING
TIME
ELAPSED TIME
CLOCK RUNNING
TIME
ELAPSED TIME
CLOCK RUNNING
TIME
ELAPSED TIME
CLOCK RUNNING
TIME
ELAPSED TIME
CLOCK RUNNING
TIME
ELAPSED TIME
CLOCK RUNNING
TIME
ELAPSED TIME
CYCLE TIME
Total Total
Example: Time Observation SheetExample: Time Observation SheetPROCESS NAME PART No.
OPERATOR CYCLE TIMEo DATE OBSERVER
Write “Talk with Data" Data #1 MACHINE: __________________CYCLE TIMEo 3/8/99 M. Smith
OBSERVED CYCLES
ORDER OF OPERATION / ELEMENT OPERATION / ELEMENT DESCRIPTION 1 2 3 4 5 6 7 8 9 10 11 12
Most Repeatable Operation/
Element Time
Best Repeatable Operation/
Element Time REMARKS
1 Stand up and walk to boardCLOCK
RUNNING TIME 5 20 35 48 1:02 10 24 35 49 2:00 15 30
ELAPSED TIME
2 Write “Talk with Data" on boardCLOCK
RUNNING TIME 10 25 38 53 5 15 27 40 52 5 20 3:00 Talking to an operator
ELAPSED TIME
3 Walk back to chair and sit downCLOCK
RUNNING TIME 15 30 43 58 8 20 30 45 55 10 25 5
ELAPSED TIME
CLOCK RUNNING
TIME
ELAPSED TIME
CLOCK RUNNING
TIME
ELAPSED TIME
CLOCK RUNNING
TIME
ELAPSED TIME
CLOCK RUNNING
TIME
ELAPSED TIME
CLOCK RUNNING
TIME
ELAPSED TIME
CLOCK RUNNING
TIME
ELAPSED TIME
CLOCK RUNNING
TIME
ELAPSED TIME
CYCLE TIME
Total Total
0
X
PROCESS NAME PART No.OPERATOR CYCLE TIMEo DATE OBSERVER
Write "Growtth" Growtth #1 MACHINE: __________________CYCLE TIMEo 3/8/99 M. Smith
OBSERVED CYCLES
ORDER OF OPERATION / ELEMENT OPERATION / ELEMENT DESCRIPTION 1 2 3 4 5 6 7 8 9 10 11 12
Most Repeatable Operation/
Element Time
Best Repeatable Operation/
Element Time REMARKS
1 Stand up and walk to boardCLOCK
RUNNING TIME 5 20 35 48 1:02 10 24 35 49 2:00 15 30
ELAPSED TIME 5 5 5 5 4 2 4 5 4 5 5 5 5 42
CLOCK RUNNING
TIME 10 25 38 53 5 15 27 40 52 5 20 3:00 Talking to an operator
ELAPSED TIME 5 5 3 5 3 5 3 5 3 5 5 30 5 33 Walk back to chair and sit down
CLOCK RUNNING
TIME 15 30 43 58 8 20 30 45 55 10 25 5
ELAPSED TIME 5 5 5 5 3 5 3 5 3 5 5 5 5 3CLOCK
RUNNING TIME
ELAPSED TIME
CLOCK RUNNING
TIME
ELAPSED TIME
CLOCK RUNNING
TIME
ELAPSED TIME
CLOCK RUNNING
TIME
ELAPSED TIME
CLOCK RUNNING
TIME
ELAPSED TIME
CLOCK RUNNING
TIME
ELAPSED TIME
CLOCK RUNNING
TIME
ELAPSED TIME
CYCLE TIME 15 15 13 15 10 12 10 15 10 15 15 40 15 10Total Total
0
X
Example: Time Observation SheetExample: Time Observation Sheet
Write “Talk with Data" on board
1. Process Name: Record the appropriate local name for the process being observed.
2. Part Number: Record the appropriate Part Number and/or Code Number that is
associated with the process being observed.
3. Operator Cycle Time: Place a checkmark (√) in the box if this process is operator
specific.
4. Machine: / Cycle Time: If the operation is machine specific, enter the Machine Number
and place a checkmark (√) inside the Machine Cycle Time Box.
5. Date: Enter the date that the process is being observed in the space
provided in the document.
6. Observer: Enter the name of the individual observing the process.
Procedure: Time Observation SheetProcedure: Time Observation Sheet
7. Order of Operation / Element: Record the steps being performed in the appropriate numerical
sequence; i.e., #1, #2, #3, #4, etc.
8. Operation / Element Description: Describe the unique step or event being observed.
9. Clock Running Time:Prior to observing the first step in the process, ensure that the
stopwatch is set on zero. For the first step in the cycle, the clock running time entered will be zero. For each step thereafter, record the actual clock
running time accumulated. The observer will be completing each of the clock running time boxes in a vertical manner throughout the completion
of the cycles. The observer will continue this procedure for at least 10 to 12 complete cycle repetitions.
10. Elapsed Time:Upon completion of 10 to 12 observations of the complete process cycle, it will be necessary to calculate the specific elapsed times for
each process step. To calculate the actual elapsed time for any given element (step), subtract the clock running time of the following element from the desired element clock running time. Example: for element #1,
9a minus 9 equals 10.
Procedure: Time Observation SheetProcedure: Time Observation Sheet
11. Most Repeatable Operation/Element Time:In the designated box for each element of the process, record the most repeated observed time. Total the times and write the total cycle time
in the box provided at the bottom of the column.
12. Best Repeatable Operation/Element Time:In the designated box for each element of the process, record the best repeated observed time. Total the times and write the total cycle time
in the box provided at the bottom of the column.
13. Remarks:Any information, situation, or circumstance impacting the observation
needs to be recorded in this section.
14. Cycle Time:Record in the bottom boxes the cumulative elemental elapsed times for
each of the cycles that were observed.
Procedure: Time Observation SheetProcedure: Time Observation Sheet
15’
30’
45’
60’
75’
90’Time
Operator
13
4
52
Takt Time
Cycle Time / Takt Time Bar ChartCycle Time / Takt Time Bar Chart
Cycle Time / Takt Time Bar ChartCycle Time / Takt Time Bar Chart
s Graphical comparison of Takt Time versus operator cycle time or machine cycle time.
s Determine proper manning in the work area.
s Determine if machines have sufficient capacity.
s Graphical comparison of Takt Time versus operator cycle time or machine cycle time.
s Determine proper manning in the work area.
s Determine if machines have sufficient capacity.
Cycle Time / Takt Time Bar ChartCycle Time / Takt Time Bar Chart
Process Name Part No. Prepared By
Date
BEFORE GROWTTH Sum of Operators Cycle Times =
Takt Time
Machine Only
Operator & Machine
Operator Only
After Growtth Sum of Operators Cycle Times =Takt Time
# of Operators (Initial Target)
Sec
onds
# of Operators
Sec
onds
Operations1. Pickup material - 2 seconds
2. Walk to Ream Machine - 2 seconds 3. Unload / Load - 20 seconds
4. Ream Processing Time - 22 seconds5. Walk to Mill machine - 4 seconds
6. Unload / Load - 10 seconds7. Mill Processing Time - 40 seconds8. Walk to Raw Material - 6 seconds
Information for Example Cycle Time / Takt Time Bar Chart Information for Example Cycle Time / Takt Time Bar Chart
Center DrillBC-300
Operations1. Pick up Material - 2 seconds2. Walk to machine - 2 seconds3. Unload / Load - 10 seconds
4. Center Drill Processing Time - 32 seconds5. Walk to inspection table - 2 seconds6. Inspect part and aside - 4 seconds7. Walk to Raw Material - 2 seconds
ChamferDX-285
Operations1. Pick up Material - 2 seconds2. Walk to machine - 2 seconds
3. Unload / Load - 6 seconds4. Chamfer Processing Time - 20 seconds
5. Walk to Raw Material - 2 seconds
Note: Processing Time = Machine Time Only
Inspect and Pack
ReamDE-501
MillXL-601
Process Name Part No. Prepared By
Machining XM-35Date
BEFORE GROWTTH Sum of Operators Cycle Times = 78
Takt Time 36
4035 Machine Only
3025 Operator & Machine
2015 Operator Only
1050
Sec
ond
s
M. Smith
3/8/99
Takt Time = 36 seconds
12
44
Operator #1 Operator #2 Operator #3
=
(Initial Target)
2.17 Operators Needed
Constraint Bottleneck
Example: Cycle Time / Takt Time Bar ChartExample: Cycle Time / Takt Time Bar Chart
Identifies constraint bottlenecks and manning requirements.
Identifies capacity constraints.
Process Name Part No. Prepared By
Machining XM-35Date
BEFORE GROWTTH Sum of Operators Cycle Times = 78
Takt Time 36
50454035 Machine Only
3025 Operator & Machine
2015 Operator Only
1050
Sec
onds
M. Smith
3/8/99
Takt Time = 36 seconds
MCT = 50
Center Drill Chamfer Mill
=
(Initial Target)
2.17 Operators Needed
MCT = 42
MCT = Machine Cycle Time
MCT = 26
MCT = 42
Ream
Capacity Constraints
Example: Cycle Time / Takt Time Bar ChartExample: Cycle Time / Takt Time Bar Chart
1. Header Information (Process Name, Part Number, Prepared By, Date): Complete the header information as required by filling out the appropriate boxes. The information should agree with the Time Observation Sheet and
the Standard Operations Routine Sheet.
BEFORE CI:
2. Prepare an appropriate scale for this graph. The scale should be written in along the “Y” axis (left hand, vertical axis) of the chart. The “Y” axis will indicate the time segments, either in seconds or minutes, needed to record actual times observed for the operators and or machines. The “X” axis (horizontal line) of the chart will indicate either operators or machines.
3. At the appropriate level, draw in the Takt Time line.
1. Header Information (Process Name, Part Number, Prepared By, Date): Complete the header information as required by filling out the appropriate boxes. The information should agree with the Time Observation Sheet and
the Standard Operations Routine Sheet.
BEFORE CI:
2. Prepare an appropriate scale for this graph. The scale should be written in along the “Y” axis (left hand, vertical axis) of the chart. The “Y” axis will indicate the time segments, either in seconds or minutes, needed to record actual times observed for the operators and or machines. The “X” axis (horizontal line) of the chart will indicate either operators or machines.
3. At the appropriate level, draw in the Takt Time line.
Procedure: Cycle Time / Takt Time Bar ChartProcedure: Cycle Time / Takt Time Bar Chart
4. Bar Charting: Create a bar chart for the total cycle time for each operator and/or machine in the process. This will be drawn in on the graph format and labeled appropriately. Each operator and/or machine will have a separate bar on the chart. Use the legend at the side of the chart to visually show if the time is:
a) Machine Only, b) Operator & Machine, and c) Operator Only.
5. Calculations: In the upper right hand corner of the worksheet, the formula for the operator requirements calculation is written. It is: Operator cycle times (in total) divided by the Takt Time. Total all of the operator cycle times as charted on the Bar Chart, and place this number in the numerator portion of the equation. Write in the calculated Takt Time in the denominator of the calculation and perform the division. The quotient of this calculation is the total number of operators required. Place the quotient (total number of operators required) in the space provided under the calculation. Perform the same calculations when dealing with machines.
6. After CI: This section is handled in the same manner as described above. It should be used to display the results of the project after improvements to the process have been made. In fact this section is part of the documentation prepared to demonstrate the results of the CI activity.
4. Bar Charting: Create a bar chart for the total cycle time for each operator and/or machine in the process. This will be drawn in on the graph format and labeled appropriately. Each operator and/or machine will have a separate bar on the chart. Use the legend at the side of the chart to visually show if the time is:
a) Machine Only, b) Operator & Machine, and c) Operator Only.
5. Calculations: In the upper right hand corner of the worksheet, the formula for the operator requirements calculation is written. It is: Operator cycle times (in total) divided by the Takt Time. Total all of the operator cycle times as charted on the Bar Chart, and place this number in the numerator portion of the equation. Write in the calculated Takt Time in the denominator of the calculation and perform the division. The quotient of this calculation is the total number of operators required. Place the quotient (total number of operators required) in the space provided under the calculation. Perform the same calculations when dealing with machines.
6. After CI: This section is handled in the same manner as described above. It should be used to display the results of the project after improvements to the process have been made. In fact this section is part of the documentation prepared to demonstrate the results of the CI activity.
Procedure: Cycle Time / Takt Time Bar ChartProcedure: Cycle Time / Takt Time Bar Chart
Part Process Capacity SheetPart Process Capacity Sheet
s Determine maximum output of a work center, machine group and / or cell.
s Identify machine bottlenecks.s One Part Process Capacity Sheet
should be calculated for all parts and all processes within the workcenter being observed.
s Determine maximum output of a work center, machine group and / or cell.
s Identify machine bottlenecks.s One Part Process Capacity Sheet
should be calculated for all parts and all processes within the workcenter being observed.
Part Process Capacity SheetPart Process Capacity Sheet
s Information needed for calculation:s Process Names Part Numbers Net Operating Time and number of shiftss Daily Requirements Time observations of machines and
operatorss Frequency of tool change, time per tool
change, and number of pieces per tool change (Not setup)
s Information needed for calculation:s Process Names Part Numbers Net Operating Time and number of shiftss Daily Requirements Time observations of machines and
operatorss Frequency of tool change, time per tool
change, and number of pieces per tool change (Not setup)
Part Process Capacity SheetPart Process Capacity SheetPROCESS NAME PART No. Necessary Quantity Per Day PREPARED BY
Net Operating Time (sec.) DATE
BASIC TIME (sec) TOOL CHANGE TIME (SEC.)
ORDER OF OPERATIONS OPERATION DESCRIPTION MACHINE No.
MANUAL OPERATION
TIME
MACHINE PROCESSING
TIMECOMPLETION
TIME PER PIECE CHANGE TIMENo. OF PIECES PER CHANGE
TIME PER PIECE
TOTAL TIME PER PIECE
DAILY PRODUCTION CAPACITY COMMENTS
Total Operator Cycle Time MAX. OUTPUT
Operations1. Pickup material - 2 seconds
2. Walk to Ream Machine - 2 seconds 3. Unload / Load - 20 seconds
4. Ream Processing Time - 22 seconds5. Walk to Mill machine - 4 seconds
6. Unload / Load - 10 seconds7. Mill Processing Time - 40 seconds8. Walk to Raw Material - 6 seconds
Information for Example Part Process Capacity Sheet Information for Example Part Process Capacity Sheet
Center DrillBC-300
Operations1. Pick up Material - 2 seconds2. Walk to machine - 2 seconds3. Unload / Load - 10 seconds
4. Center Drill Processing Time - 32 seconds5. Walk to inspection table - 2 seconds6. Inspect part and aside - 4 seconds7. Walk to Raw Material - 2 seconds
ChamferDX-285
Operations1. Pick up Material - 2 seconds2. Walk to machine - 2 seconds
3. Unload / Load - 6 seconds4. Chamfer Processing Time - 20 seconds
5. Walk to Raw Material - 2 seconds
Note: Processing Time = Machine Time Only
Inspect and Pack
ReamDE-501
MillXL-601
Information for Example Part Process Capacity SheetInformation for Example Part Process Capacity Sheet
s Process Name - Center Drill, Chamfer, Ream and Mills Part Number - XM-35s Net Operating Time = 420 minutes or 25,200 secondss One shift operations Daily Requirement = 700 unitss Tool Change Time Data:
s Process Name - Center Drill, Chamfer, Ream and Mills Part Number - XM-35s Net Operating Time = 420 minutes or 25,200 secondss One shift operations Daily Requirement = 700 unitss Tool Change Time Data:
Machine Number ofPieces per
Tool Change
ChangeTime
(minutes)Center Drill 200 10
Chamfer 80 50
Ream 150 20
Mill 90 40
Formulas: Part Process Capacity SheetFormulas: Part Process Capacity Sheet
Tool Change Time Per
Piece
=Time per Tool
ChangeNumber of Piece Per Tool Change
Completion Time = +
Manual Operation
Time
Machine Processing
Time
Daily Production Capacity
= Net Operating TimeCompletion
Time Per Piece
Tool Change Time per
Piece
+
Example: Part Process Capacity SheetExample: Part Process Capacity SheetPROCESS NAME PART No. Necessary Quantity Per Day PREPARED BY
Machining XM-35 700 M. Smith
Net Operating Time (sec.) - (H) DATE
25,200 3/ 8/ 99
BASIC TIME (sec) TOOL CHANGE TIME (SEC.)
ORDER OF OPERATIONS OPERATION DESCRIPTION MACHINE No.
MANUAL OPERATION
TIME
MACHINE PROCESSING
TIMECOMPLETION
TIME PER PIECE CHANGE TIMENo. OF PIECES PER CHANGE
TIME PER PIECE
TOTAL TIME PER PIECE
DAILY PRODUCTION CAPACITY COMMENTS
A + B = C D E D/ E=F C+F=G H/ G
1 Center Drill BC-300 10 32 42 600 200 3 45 560
Total Operator Cycle Time MAX. OUTPUT
1. Process Name: Record the appropriate local name of the process for which capacity is being calculated.
2. Part Number: Record the specific Part Number and/or Code Number that is associated with the process.
3. Necessary Quantity Per Day / Takt Time: Record in the box the predetermined demand quantity and Takt Time for the identified part
number involved in this process. This number should be available from the facility’s Production Planning Department.
4. Net Operating Time (seconds): Record in the box the number of seconds actually available for scheduled operations. The net operating time excludes scheduled breaks, cleanup, lunch, routine meetings, etc.
5. Prepared By: Record in the specified box the name of the individual and his/her position (John Doe, supervisor) completing the PPCS.
6. Date: Record in the box the date that the sheet was completed.
Procedure: Part Process Capacity SheetProcedure: Part Process Capacity Sheet
7. Order of Operations: Record the steps being performed in the appropriate numerical sequence: i.e., #1, #2, #3, #4, etc.
8. Operation Description: Describe the unique step (event).
9. Machine Number (Machine No.): Enter the appropriate Machine Number or identifier in the space provided.
10. Basic Time (seconds):a) Manual Operation Time: Record the time it takes the operator to
physically unload the identified part and to load a new part into the machine and begin the process. Be sure to include the time to manually operate the
machine if the machine is not automatic.b) Machine Processing Time: Record the time necessary for the
machine to complete one automatic cycle of the operation. This time begins with activating the start button and concludes with the part ready for
unloading. c) Completion Time Per Piece: For each unique operation and
machine, total the Manual Operation Time and the Machine Processing Time. Manual +Machine = Completion Time.
Procedure: Part Process Capacity SheetProcedure: Part Process Capacity Sheet
11. Tool Change Time (seconds):a) Change Time: Record the total number of seconds required to
exchange the above mentioned tooling in the identified machine. This is not setup and/or tear-down time in changing from one part to a different
part on this piece of equipment.b) Number of Pieces Per Change: Record the total number of parts or
pieces that are typically produced before changing the tooling due to normal wear. This can also be used for sample runs.
c) Time Per Piece: Record the quotient of Change time divided by Number of pieces per change. This establishes the time per piece
required for tooling changes.
12. Total Time Per Piece:Add the Completion Time Per Piece (#10c) in the “Basic Time
Category” to the Time Per Piece calculation in the “Tool Change Time Category” to derive the Total Time Per Piece.
Procedure: Part Process Capacity SheetProcedure: Part Process Capacity Sheet
13. Daily Production Capacity:This is the total number of units for this part that can be produced in this
process during the Net Operating Time. Net Operating Time
Daily Production Capacity = ______________________ Total Time Per Piece
14. Comments: This section is provided to give the user space to write pertinent comments concerning the observations. An example of a “
pertinent” comment might be the fact that a new operator is performing the tasks. This new operator may be having difficulty due to a lack of
familiarity with the operation.
15. Maximum Output: In the space provided, total the maximum output for the day based on the production capacities recorded. The maximum output is equal to the output of the “most limiting” operation (the lowest number
of the Daily Production Capacity).
16. Total Operator Cycle Time: Summarize the total Manual Operation Time in the Total Operator Cycle Time space provided.
Procedure: Part Process Capacity SheetProcedure: Part Process Capacity Sheet
Standard Operations:Operator Routine SheetStandard Operations:Operator Routine Sheet
s Identifies operator / machine’s work routine.
s Develops the best sequence of operations for operator / machines.
s Standard Operations: Operator Routine Sheet per operator in workcenter.
s Identifies operator / machine’s work routine.
s Develops the best sequence of operations for operator / machines.
s Standard Operations: Operator Routine Sheet per operator in workcenter.
Standard Operations:Operator Routine SheetStandard Operations:Operator Routine Sheet
Operations1. Pickup material - 2 seconds
2. Walk to Ream Machine - 2 seconds 3. Unload / Load - 20 seconds
4. Ream Processing Time - 22 seconds5. Walk to Mill machine - 4 seconds
6. Unload / Load - 10 seconds7. Mill Processing Time - 40 seconds8. Walk to Raw Material - 6 seconds
Information for Example Standard Operations: Operator Routine Sheet Information for Example Standard Operations: Operator Routine Sheet
Center DrillBC-300
Operations1. Pick up Material - 2 seconds2. Walk to machine - 2 seconds3. Unload / Load - 10 seconds
4. Center Drill Processing Time - 32 seconds5. Walk to inspection table - 2 seconds6. Inspect part and aside - 4 seconds7. Walk to Raw Material - 2 seconds
ChamferDX-285
Operations1. Pick up Material - 2 seconds2. Walk to machine - 2 seconds
3. Unload / Load - 6 seconds4. Chamfer Processing Time - 20 seconds
5. Walk to Raw Material - 2 seconds
Note: Processing Time = Machine Time Only
Inspect and Pack
ReamDE-501
MillXL-601
Procedure Standard Operations:Operator Routine SheetProcedure Standard Operations:Operator Routine Sheet
1. Header Information: a) Process Name: Enter the Process Name for the operations being charted.b) Part Number: Record the Part Number being processed.c) Employee’s Name and Position: Enter the name of the employee and the employee’s position.d) Date: Enter the date that the SOORS is being prepared.e) Necessary Quantity per Day: Enter in the space provided the customer demand required (number of units).f) Takt Time: Calculate Takt Time as follows:
Net Operating Time Per Day______________________ Units Required Per Day
(Express Takt Time in seconds or minutes.)
2. Order of Operations: Record the operations being performed in the appropriate numerical sequence; i.e. #1, #2, #3, #4, etc.
Procedure Standard Operations:Operator Routine SheetProcedure Standard Operations:Operator Routine Sheet
3. Operation Description:Enter a complete description of each operation.
4. Basic Time: a) Manual Operation Time (seconds): Using the Part/Process Capacity Sheet, enter the time in the space provided for each step of the manual process.
b) Machine Processing Time (seconds): Enter in the space provided the automatic machine processing time
c) Walk Time: Enter the Walk Time in the space provided.
5. Operations Time:a) Takt Time: Draw a vertical line at the appropriate point to indicate the Takt Time in seconds or minutes to fit the scale.
b) Activity Plots: Using the Activity Key provided in the upper right hand column of the standard operations operator routine sheet, draw the appropriate line, in accordance with the time (seconds) required.
ACTIVITY KEYManual Operation = Solid LinesMachine Processing = Dotted LinesWaiting = Double lineWalking = Wavy Line
Procedure Standard Operations:Operator Routine SheetProcedure Standard Operations:Operator Routine Sheet
NOTES:
s The Manual Operation and Machine Processing Times for the first machine are initially drawn on this sheet by taking the data from the Part/Process Capacity Sheet.
s In determining subsequent operations for the operator, be sure to make time allowances for quality inspection and safety precautions.
s If the final line meets the Takt Time, the operations routine is an appropriate mix.
s If the final line ends before the Takt Time, determine if more operations can be added.
s If the final line exceeds the Takt Time, determine ways to shorten the operations time.
NOTES:
s The Manual Operation and Machine Processing Times for the first machine are initially drawn on this sheet by taking the data from the Part/Process Capacity Sheet.
s In determining subsequent operations for the operator, be sure to make time allowances for quality inspection and safety precautions.
s If the final line meets the Takt Time, the operations routine is an appropriate mix.
s If the final line ends before the Takt Time, determine if more operations can be added.
s If the final line exceeds the Takt Time, determine ways to shorten the operations time.
Procedure Standard Operations:Operator Routine SheetProcedure Standard Operations:Operator Routine Sheet
Standard Operations:Operator Routine Sheet
Standard Operations:Operator Routine Sheet
Concentration and Spaghetti Diagrams Concentration and Spaghetti Diagrams
Continuous Improvement TrainingContinuous Improvement Training
Concentration DiagramConcentration Diagram
What is a Concentration Diagram?
What is a Concentration Diagram?
s Concentration Diagram: A simple graphical way to show frequencies of issue
occurrence.s You may wish to think of it as a picture-
like Fishbones What does it do?s Non confrontational voting
s Allows those doing the diagram to discover “concentrations” that may point to causes
s Simply, it can help show problem areas on a product or process
s Concentration Diagram: A simple graphical way to show frequencies of issue
occurrence.s You may wish to think of it as a picture-
like Fishbones What does it do?s Non confrontational voting
s Allows those doing the diagram to discover “concentrations” that may point to causes
s Simply, it can help show problem areas on a product or process
Example #1 --- Concentration Diagram
Example #1 --- Concentration Diagram
Example #2 --- Concentration Diagram
Example #2 --- Concentration Diagram
Spaghetti DiagramSpaghetti Diagram
What is a Spaghetti Diagram?What is a Spaghetti Diagram?s Spaghetti Diagram: A simple graphical map
showing the path taken by a specific product/process as it travels down the value stream process.
s What does it do?s Shows process flow, and encourages team
members to think in terms of relationships (multiple directions) rather than linearly
s Provides an initial indication of potential cause and effect relationships
s Can facilitate the emergence of key issues rather than issues from a dominant team member
s Can foster discussion and challenge team assumptions about the process or area
s Spaghetti Diagram: A simple graphical map showing the path taken by a specific product/process as it travels down the value stream process.
s What does it do?s Shows process flow, and encourages team
members to think in terms of relationships (multiple directions) rather than linearly
s Provides an initial indication of potential cause and effect relationships
s Can facilitate the emergence of key issues rather than issues from a dominant team member
s Can foster discussion and challenge team assumptions about the process or area
Spaghetti DiagramSpaghetti Diagram
s Flows of metals within a metal usage process
Spaghetti ChartsSpaghetti Charts Functional cluster within
the engineering departments lead to
extensive travel of job files and engineers. Contact between
reviewer, engineer and checker require additional walking.
The layout does not encourage short communications
between senior and less experienced
engineers.
Spaghetti – Machine cell planningSpaghetti – Machine cell planning
Reduction in travel time, waiting, WIPImprovement of ergonomics, visibility,
flexibility
Reduction in travel time, waiting, WIPImprovement of ergonomics, visibility,
flexibility
Construction tipsConstruction tips
s Project from PC onto whiteboard/flipchart and draw around image
s If you expect to move furniture/machines Cut out post-its to show the plan. These can be moved easily
s Apply Nominal group technique and use Post-its on a wall to build or Fishbone concentration diagram
s If you have transparencies you can build up layers corresponding to different operators/processes
s Photograph/Photocopy/Scan the result
s Project from PC onto whiteboard/flipchart and draw around image
s If you expect to move furniture/machines Cut out post-its to show the plan. These can be moved easily
s Apply Nominal group technique and use Post-its on a wall to build or Fishbone concentration diagram
s If you have transparencies you can build up layers corresponding to different operators/processes
s Photograph/Photocopy/Scan the result
SummarySummary
s Tools help collect and organize data.
s Tools help identify areas of opportunities graphically.
s All data collected will be used for the project - therefore data integrity is important.
s Tools help collect and organize data.
s Tools help identify areas of opportunities graphically.
s All data collected will be used for the project - therefore data integrity is important.
Lean ToolsLean Tools
Continuous Improvement TrainingContinuous Improvement Training