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Welcome to the TAKT Time and RR Calc. module. In this class, we will introduce you to some common capacity calculations used at Jabil. These include Takt Time, Run Rate, Cycle Time, Units per Hour (UPH), and Units per Person Hour (UPPH). We will show you the formulas for each of these and also provide you a link to a tool that you can use to assist in performing these calculations..

[Audio] By the end of this module, you will have a better understanding of Takt Time, how to calculate it, how Takt Time is used to define the quantity of resources needed in a process and how to define Run rate, Units Per Hour and Units Per Person Hour..

[Audio] Takt Time is the frequency at which a product must be produced in order to satisfy the customer demand..

[Audio] Takt Time is calculated by dividing the Total effective working time in a defined period by the Customer demand in that period of time. The Total working time must deduct the time for breaks, programmed maintenances, improvement programs, ….. For example: Lets say you have 510 minutes available in the shift. If the breakfast time is 20 minutes, lunch is 30 minutes, the cleanup time is 5 minutes, and there are 5 minutes for health breaks, this adds up to 60 minutes. We subtract the 60 minutes from the initial 510 and get 450 minutes remaining..

[Audio] In this example, The total available time for production is 8 Hrs; to have the Total working time we need to deduct ; 5 min of the 5s program, 10 minutes for programmed maintenance, 30 minutes of lunch, and 15 minutes of programmed changeover, that gives a total working time of 7 Hrs. Takt time is usually expressed In seconds, by dividing the 7 Hrs by 420 units of demand, it give us a Takt Time of 60 Seconds. Please take note that when Takt Time falls below ten seconds the operator's work may become highly repetitive and stressful, conversely when Takt Time goes beyond 120 seconds the work motions can be difficult to standardize..

[Audio] Takt Time is a variable; customer demand can change over time and also manufacturing can change the Scheduled Run Time. The goal is to design the manufacturing process that's flexible enough to operate effectively over a range of Takt Times Working at the pace of Takt Time is important to avoid or reduce waste of over production and waiting times. Calculation of a single Takt Time for a program is meaningless in designing a manufacturing system, it is more important to understand the range of possible Takt Times and the timing of those changes..

[Audio] A cycle Time is the time it takes to complete one cycle of an operation, from the start of the operation until the operator (or machine) is ready to start the same operation again. It's important to note that Cycle time is different than Takt Time. If an operation has Cycle time higher than Takt Time, the operator can´t keep up with the pace of production causing inventories to pile up, but if an operation has Cycle time lower than Takt Time the operator will be waiting for units from previous operations. In both cases it is not an efficient situation. The goal is to balance cycle time to match Takt time..

[Audio] In a production process to avoid waste, the target is to match the cycle time of each operation to Takt Time. The cycle time is shown by CT for each element of work. The Cycle times vary from 9.2, 9.5, 9.9...but the highest one shown in red is 10 seconds. The output from the process shown in this diagram is one unit every ten seconds, because it is the highest cycle time of one of the feeder process of the main line..

[Audio] The quantity of resources needed in a process is calculated by dividing the Total process cycle time by the Takt Time. Here's an example. Let's say we have a process that has a total cycle time of 230.23 seconds, and a TAKT time of 37.25 seconds. That would give us 6.18 resources needed. But you can't have an 18th of an operator. If no improvement is made to lower that 6.18 to 6, the result will be lower productivity by using 7 operators in the process..

[Audio] When having a Mix of products these formulas can be used to calculate the Takt Time and the Resources needed..

[Audio] Run rate is the target rate of production to satisfy the customer demand. You get the run rate by dividing the Demand in a defined time period by the working time in that period. Let's say we have a customer that wants 5,160 assemblies per month and there are 20 working days in that month. When you divide the demand by the days, you get 258 assemblies per day that will be needed to meet the customer demand..

[Audio] Units Per Hour (UPH) is the typical measure used in the manufacturing process to asses the efficiency of personal and production systems. In it simple form, Units per hour is calculated by dividing the quantity of units to produce in a period of time by the hours worked in that period of time..

[Audio] To have accurate data it is necessary to deduct the breaks and unplanned production periods from the workday hours..

[Audio] Units Per Person Hour is an important metric to measure line performance and also help to compare different process set up such as units produced, hours and operators. Units Per Person Hour (UPPH) is calculated by dividing the quantity of units produced in a period of time by the hours worked in that period of time (UPH), divided by the quantity of operators that work to produce that units. Let's look at two examples. In example 1, we have 1000 units produced in 1 0 hours with 10 operators. This gives us a UPPH of 10. But if we look at another line that produces more output in the same time with more operators, we get a UPPH of 9.47. Comparing the two examples you can see that in the second line each operator produces less output which results in more operation cost..

[Audio] This is an example of a template that can be used to calculate the Takt Time, Run rate, UPH, UPPH and Resources. You can access this tool by clicking the link here. Pls.http://gos/IE/Reference%20Materials/Resource%20analysis%20file.xls.