Comprehensive Calculator Guide
This calculator works out cycle time, the average time to make one unit, from net running time and units produced, and compares it with the takt time customer demand requires. 480 minutes producing 120 units is a 4-minute cycle, 15 units an hour. With demand of 150, takt time is 3.2 minutes and current capacity covers only 80% of demand.
Cycle time vs takt time
Cycle time is what you achieve: running time ÷ units made. Takt time is what the market needs: available time ÷ demand. If cycle time is longer than takt, the line can’t keep up.
Lead time is different: the time from order to delivery, including waiting and shipping. The slowest step, the bottleneck, sets the output of the whole line.
How to Use
- Enter net running time in minutes, after breaks and planned stops.
- Enter units produced, and demand for the same period to compare.
- Press “Calculate cycle time” to see time per unit, output per hour and the comparison with demand.
Formula Used
Cycle time = running time ÷ units | Takt time = running time ÷ demand | Capacity = takt ÷ cycle × 100
Practical Examples
- Example 1: short of demand
- 480 minutes, 120 units, demand 150: cycle 4 min (15 an hour), takt 3.2 min, capacity 80%.
- Example 2: spare capacity
- 450 minutes, 300 units, demand 250: cycle 1.5 min (40 an hour), takt 1.8 min, capacity 120%.
Important Tips
- Use actual running time, not shift length.
- Time each step to find the bottleneck.
- Track cycle time weekly to see the effect of changes.
Common Mistakes to Avoid
- Dividing the whole shift by units.
- Counting defective units as output.
- Improving a step that isn’t the bottleneck.
Frequently Asked Questions
- Cycle time vs takt time?
- Cycle time is what the line does per unit; takt time is what it must do to meet demand.
- How do I calculate cycle time?
- Running time ÷ units: 480 ÷ 120 = 4 minutes a unit.
- What if cycle time exceeds takt?
- Speed up the bottleneck, add time, people or a line, or reschedule orders.