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Cell 4 Layout Kaizen

April 9 to 13, 2007

For Internal Use Only

TAKT time and rhythmic capacity

For Internal Use Only

For Internal Use Only

Find solutions to meet the demand

– TAKT time and
– Rhythmic capacity of the line
TAKT : German word meaning the
baton of the bandmaster

081006 RevR1
For Internal Use Only

Calculating the TAKT time

– A local general contractor is

entrusted to a mega housing
development project.
– The contractor has to build
1000 houses over the course of
a year.
– One house consists of 7200
FBM of lumber.
– You operate the only sawmill in
the region.
– What is your TAKT time in
order to supply this demand?

081006 RevR1
For Internal Use Only

Calculating the TAKT time

• Available time per day • Customer’s demand

• (1 shift)
• = 2000 m3 for Timmins
• = 1200 m3 for Ostrum
• = 11 hours = 660 minutes • = 3200 m3
• - breaks 30 minutes • = 3200 m3 per day
• - lunch 30 minutes
• = 600 minutes available

081006 RevR1
For Internal Use Only

Calculating the TAKT time

•The TAKT time is:

600 minutes available

= 3,200 m3 required (customer's need)

•=0.1875 minutes per m3 (x 60 = 11.3 seconds per m3) = TAKT

•1m3=11.3 seconds
•1 minute=5.33m3 (1x60\11.3)
•5.33m3\0.203(avg vol/tree)
•=(26.25) or 27 trees/minute
•=27 trees / # bunchers(13)=2.1 trees per minute per buncher
•Or 60 seconds / 27 trees=2.22 seconds per tree

081006 RevR1
For Internal Use Only

Cycle time vs TAKT time

2x4
M/C 5 M/C 4
complétée

M/C 3 TAKT : 4.8 MINUTES

Billot M/C 1 M/C 2

Cycle time of line :

1 ton each 3.8 minutes
OK 0 0.3 0.6 0.9 1.2 1.5 1.8 Minutes

M/C 1

M/C 2

M/C 3

M/C 4

M/C 5

Réglage Transformation
081006 RevR1
For Internal Use Only

Woodlands TAKT time:

• Available time per week: • Demand per week:

• 84 hours – • 6,500 m3 / week / 2.5 bunchers

lunches/breaks/fuelling/greasing
(12 hours) = 72 hours • = 2,600m3 per buncher per wk

• 72 hours available time • Volume = 0.135m3 per tree

• = 2,600m3/0.135 = 19,260 trees

per week

081006 RevR1
For Internal Use Only

Woodlands TAKT time cont.:

• 72 hours available x 60 • 0.22 minutes per tree = TAKT

• = 4320 minutes available • 0.22 minutes x 60

• 19,260 trees
• = 13.2 seconds per tree
• = 0.22 minutes per tree = TAKT

TAKT time = 13.2 sec.

081006 RevR1
For Internal Use Only

Presentations

• Be back here at

•
for your presentations
081006 RevR1
TAKT time and rhythmic capacity

For Internal Use Only

For Internal Use Only

Find solutions to meet the demand

 TAKT time and

 Rhythmic capacity of the line

TAKT : German word meaning the

baton of the bandmaster

081006 RevR1 12
For Internal Use Only

Calculating the TAKT time

 A Customer requests 100 Tons of a new grade of paper,
to be delivered within the next two weeks.
 Our Production Schedule is reviewed to determine if
there is available time to manufacture this Grade.
 The Backlog Schedule indicates that there are 10 Open
Hours on the Paper Machine, however our productive
rate indicates a Rhythmic Capacity problem in the
process.
 The Cycle Time for coating is in excess of our Paper
Machine capabilities .
 What can be done?

081006 RevR1 13
For Internal Use Only

Calculating the TAKT time

Cycle Capacities: Available time – 10 Hours

Pulper: Demand – 100 Tons
15 Tons/Hour
Coating Preparation: 100 Tons Of paper consisting
2 Tons/Hour of:
Paper Machine: ( 75 Tons Of Pulp )
10 Tons/Hour ( 25 Tons Of Coating )
Winder:
18 Tons/Hour The Paper Machine Cycle time
Wrapper: is 10 Tons / Hour.
12 Tons/Hour

081006 RevR1 14
For Internal Use Only

Calculating the TAKT time

Takt Time
Hours
14.0
12.0
12.5 Hr.
10.0
10.0 Hr.
8.0
8.3 Hr.
6.0
5.6 Hr.
4.0 5.0 Hr.

2.0
0.0
P ulper Coating P rep. P aper Machine Winder Wrapper
Cycle Time Cycle Time Cycle Time Cycle Time Cycle Time

081006 RevR1
For Internal Use Only

Solution, is to reduce the Takt Time

•A Kaizen was scheduled and completed to address this problem;

•Results:
•Increased pigment pump speed - decrease 2
minutes.

•Increase Mixer pump speed - decrease

3 minutes.

•Add three components at the same time instead

•of one at a time”. Batch time is now 20 minutes
•per batch and still one ton per batch.
• - decrease 5
minutes.
• 081006 RevR1 16
For Internal Use Only

Cycle time vs TAKT time

Takt Time OK
Hours
14.0

12.0

10.0
10.0 Hr.
8.0
8.3 Hr. 8.3 Hr.
6.0
5.0 Hr. 5.6 Hr.
4.0

2.0

0.0
Pulper Coating Prep. Paper Machine Winder Wrapper
Cycle Time Cycle Time Cycle Time Cycle Time Cycle Tine

081006 RevR1