Enter demand, shifts, breaks and each station’s work content to get takt time, the Yamazumi chart, the bottleneck, the minimum number of operators and the annual cost of imbalance.
Pre-sizing and estimating tool: results do not replace design, calculations or reports signed by a licensed professional, nor verification against the applicable codes and standards.
Work content of each station with the takt line (red) and planned cycle time line (orange).
Ideal split of the same total work across the theoretical minimum number of operators.
Cash flow of the improvement: investment in year 0 and annual savings escalated at the rate entered, discounted at the MARR.
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Divide available time by demand for the same period. Two 8-hour shifts with 60 minutes of breaks give 50,400 s; for 900 parts per day, takt is about 56 s.
Takt is the pace the customer asks for. Cycle time is the line’s real pace, set by the slowest station. The line meets demand only if cycle time is below takt.
Add the work content of all stations and divide by the planned cycle time, rounding up. With 290 s of work and a 52 s cycle, you need 6 operators.
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