Takt Time
The rate at which a finished product must be completed to meet customer demand.
Takt Time (German: takt = rhythm/beat) is the rate at which finished products must be produced to meet customer demand. It represents the maximum time allowed per unit to satisfy demand with available production time. Takt time acts as the "heartbeat" of production, ensuring output is synchronized with market pull rather than pushing products based on capacity.
The Formula
Takt Time = Available Production Time / Customer Demand
Example Calculation:
Available Production Time: 8 hours/day = 480 minutes
Less: Breaks (30 min), planned maintenance (10 min), meetings (20 min)
Net Available Time = 420 minutes
Customer Demand: 60 units per day
Takt Time = 420 minutes / 60 units = 7 minutes per unit
Meaning: Factory must complete one finished unit every 7 minutes to meet customer demand without overproducing or underproducing.
Why Takt Time Matters
1. Prevents Overproduction
If actual cycle time is 5 minutes but takt time is 7 minutes, factory is producing faster than demand—creating excess inventory (waste). Instead of running at full speed, production should pace itself to takt time, freeing up capacity for other products or maintenance activities.
2. Highlights Capacity Gaps
If takt time is 7 minutes but actual cycle time is 10 minutes, factory cannot meet demand with current capacity. Need to either reduce cycle time, add capacity (extra shifts, more machines), or communicate realistic lead times to customers.
3. Balances Production Lines
All operations in a production line should be designed to complete their tasks within takt time. If one operation takes 12 minutes while takt time is 7 minutes, it creates bottleneck and disrupts flow.
Real Manufacturing Example
Company: LED bulb assembly, demand = 1200 bulbs/day
Available Time Calculation:
Shift: 8 AM to 5 PM = 9 hours = 540 minutes
Less: Lunch break = 30 min
Less: Tea breaks = 20 min
Less: Line setup/changeover = 15 min
Less: Daily cleanup = 10 min
Net Available = 465 minutes
Takt Time = 465 / 1200 = 0.3875 minutes = 23.25 seconds
Implication: One completed bulb must roll off assembly line every 23 seconds to meet customer demand.
Current Cycle Times:
| Operation | Cycle Time | Status |
|---|---|---|
| PCB assembly | 18 seconds | ✅ Under takt time |
| Driver insertion | 30 seconds | ❌ Exceeds takt time |
| Cap & base assembly | 22 seconds | ✅ Under takt time |
| Testing & labeling | 20 seconds | ✅ Under takt time |
Issue: Driver insertion takes 30 seconds, exceeding 23-second takt time. This operation is the bottleneck. Entire line must wait, so actual output = 465 min / 0.5 min = 930 bulbs/day (270 units short!).
Solutions to Meet Takt Time:
- Option 1: Add second operator at driver insertion (parallel work). Both operators do 30 seconds alternately, effective cycle time = 15 seconds (now under takt time)
- Option 2: Improve method—use pneumatic driver tool instead of manual, reduces time to 20 seconds (under takt time)
- Option 3: Redesign fixture for faster component insertion (reduce to 22 seconds)
Takt Time vs Cycle Time vs Lead Time
Takt Time: Customer demand rate (how often customer needs one unit)
Cycle Time: Production rate (how often factory produces one unit)
Lead Time: Total time from order to delivery (includes waiting, processing, transport)
Ideal State: Cycle Time ≤ Takt Time (can meet demand without building inventory)
Example:
Takt Time = 10 minutes (customer needs 48 units/day)
Cycle Time = 8 minutes (factory produces 60 units/day)
Result: Overproduction of 12 units/day. Better to slow down or allocate resources elsewhere.
Takt Time = 10 minutes
Cycle Time = 15 minutes
Result: Underproduction. Can satisfy only 32 units/day instead of demanded 48. Need to improve process or add capacity.
Using Takt Time for Line Balancing
When designing or rebalancing production line, distribute work so each workstation completes its tasks within takt time:
Before Line Balancing (unbalanced):
- Station 1: 25 sec (exceeds takt time of 23 sec) ← bottleneck
- Station 2: 18 sec
- Station 3: 12 sec (half idle time!)
- Station 4: 20 sec
After Rebalancing:
- Station 1: 22 sec (moved some tasks to Station 3)
- Station 2: 18 sec
- Station 3: 21 sec (took over tasks from Station 1)
- Station 4: 20 sec
All stations now within takt time, line balanced, smooth flow achieved.
Adjusting to Demand Changes
Takt time changes when demand changes. Monthly or quarterly, recalculate takt time based on updated demand forecasts.
Scenario: Seasonal Demand Surge
Normal demand: 1000 units/day (Takt time = 28 seconds)
Festival season demand: 1500 units/day (new Takt time = 18.6 seconds)
Response Options:
- Add overtime shift (increases available time, raises takt time back up)
- Temporarily add operators at slower stations to speed up
- Remove non-value-adding activities to reduce cycle times
- Build buffer inventory before season starts (produce ahead)
Common Misunderstandings
- "Target = Zero idle time": Wrong! Takt time intentionally creates idle time at non-bottleneck operations. This is healthy—prevents overproduction
- "Faster is always better": If cycle time is 5 min and takt time is 8 min, running faster creates inventory waste. Match pace to demand
- "Takt time = target cycle time": Not exactly. Cycle time should be slightly less than takt time (85-90%) to allow buffer for unexpected issues
Implementing Takt Time Thinking
- Calculate current takt time: Based on genuine customer demand (not capacity or internal targets)
- Measure actual cycle times: Time each operation accurately
- Identify gaps: Operations exceeding takt time, operations with excessive idle time
- Rebalance: Redistribute tasks, add resources at bottlenecks, remove resources from over-capacity areas
- Visual management: Display takt time prominently at each station so operators know the pace
- Monitor and adjust: Regularly review as demand patterns change
How Karygar Calculates Takt Time
Karygar tracks actual customer orders and production schedules to calculate dynamic takt times per product. Production planning module compares takt time with operation cycle times (from time study data) to identify bottlenecks and suggest capacity adjustments. Real-time production dashboards show if lines are running ahead or behind takt time, enabling supervisors to adjust pace and prevent over/underproduction.
See Takt Time in Action
Don't just read about Takt Time. See how Karygar automates this process to reduce manual work and errors on your factory floor.