How it is calculated
Available time = (Shift length − Breaks) × Shifts per day
Takt time = Available time ÷ Customer demand
Minimum stations = Total work content ÷ Takt time (rounded up)
Worked example
A 480-minute shift with 30 minutes of breaks gives 450 minutes (27,000 s). With a demand of 450 units per day, takt is 60 seconds. If one unit needs 300 seconds of total work, you need at least 5 stations.
Practical tips
- Any station with a cycle time above takt is a bottleneck and will make you miss demand.
- Lines are usually balanced to a cycle slightly below takt (around 85–95%) to absorb variation.
- Recalculate takt when demand changes, rather than keeping the line at an old pace.
Frequently asked questions
What is the difference between takt time and cycle time?
Takt time is the pace demand requires. Cycle time is how long a station actually takes. For the line to meet demand, every cycle time must be at or below takt.
Should I subtract downtime from available time?
Subtract planned time such as breaks and meetings. Do not subtract unplanned breakdowns: they are losses to eliminate, not part of the available time.
Is takt time the same as lead time?
No. Lead time is how long one unit takes from start to finish, including waiting. Takt time is how often a finished unit must come off the line.