Takt time, cycle time, and pitch

Learning objectives

• Calculate takt time from a shift plan and customer demand.
• Compare takt with measured cycle times to expose imbalance.
• Choose an appropriate pitch for visual management.

Definitions

• Takt time = available working time ÷ customer demand within that time.
• Cycle time = actual time an operation takes for one piece.
• Pitch = takt × pack quantity used for visual scheduling.

Reading the three numbers together

If every station’s cycle time is below takt, the line theoretically meets demand. If any station’s cycle time exceeds takt, that station sets the pace and the rest of the line will wait or build WIP.

Garment-factory example

A polo line runs 8 hours minus 30 minutes of breaks, giving 27,000 seconds. The daily order is 900 pieces, so takt = 27,000 ÷ 900 = 30 seconds. The collar attach cycle time is 42 seconds. That single station is the bottleneck; balancing must reduce collar-attach content or add a second operator.

Method

1. Confirm available time in seconds, not hours, and subtract real breaks.
2. Time at least ten cycles per station and use the median for balance calculations.
3. Publish takt, cycle and pitch on the line board so the team can act.

Common mistakes

• Using scheduled hours instead of net available time.
• Comparing takt with average cycle time from one observation.