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Terms in this set (14)
Purpose of Bar Chart
A tool used to redistribute work in relation to Takt Time in a multi-step, multi-operator process to assist in the creation of continuous flow.
Manual Cycle Time
The amount of time that an opperator spends working on their process. (Touch Time)
Total Manual Cycle Time
This is the total time all of the operators in the process spend working on the product, even if some of the processes are in parallel. Found by adding all MCTs.
The amount of time available for work to be done. This does not include breaks or non-work time during paid hours, so it should be adjusted by effective utilization.
A rate to account for the time people will be taking lunch, allotted break times, trainings, etc. Typically 75-80%, this is an assumption that much be stated.
The amount of products requested by the customer.
The rate at which a finished product needs to be completed in order to meet customer demand.
Available Time / Customer Demand
Amount of paid working hours needed to fulfill customer demand. Adjusted for effective utilization so workers can take breaks as necessary during this time.
Time Required Equation
(Demand) x (Total Manual Cycle Time) / (Staffing) x (Effective Utilization)
Calculated using Time Required - Regularly Scheduled Time, results in time needed per person
Takt Time < Manual Cycle Time
We are not meeting takt; we will not meet customer demand. The process with the highest manual cycle time is the bottleneck/constraint.
Overtime Required is negative
This means there is extra capacity in the system.
Japanese for levelization - leveling the type and quantity of production over a fixed period of time.
Creating a New Bar Chart
Level the Schedule (consistent production pace)
Load the Line (produce products proportionally; avoid batching)
Balance the Workstations (assign workers accordingly)