When setting up a new process, or even a new product run through an existing work cell, you will need to have the work cell balanced to ensure every operators is performing value-added work. There are a few ways to do this, but one of the more effective methods is by using what is known as the Cycle Time vs Takt Time Bar Chart.

The way this chart works is by charting the operator cycle times on the x-axis. These operations, or cycle times, are placed in a bar form on each one of the letters. You will then do this for all of the operations within the work cell required to be performed to produce the part.

Once these bars are in place, then calculate the takt time. You can see exactly how this calculation is done with a video I put together here: Takt Time Calculation

Once you have this number, in term of seconds, then mark this time on the y-axis, and draw a straight line across, from left to right.

What you now have in front of you is a simple bar chart showing which operations are not fully loaded and which ones are potentially the bottleneck. The job of you and your team will them be to figure out how to fully load each person within the work cell, and also to lower the cycle times of whichever operations take longer than takt time.

After all, if the cycle time is longer than takt time, you will not be able to supply the customer requirements.

For further explanations, I have also included a video which will walk you through an actual example of how to use this chart:

I have made this simple bar chart available for download for free. Grab a copy now.

Download Cycle Time vs Takt Time Bar Chart

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