ABSTRACT

In this chapter, the authors discuss the results of the documentation phase of the kaizen event and start thinking about takt time and its relationship to cycle time as presented in the useful Lean analytical and visual tool called a "percent-loading chart''. The crew size, reduced cycle times, productivity gain, and lead-time reduction goals result from team countermeasures after review and brainstorming of the observed operator elements and understanding of the variations in the documented process. The percent-loading chart is a stacking of observed operator elements in time, which is then compared to takt time to determine relative position. The inventory goal will be met by embracing the basic tenets of Lean production: producing to takt time, doing it one piece at a time, and doing it at the demand of the customer. Takt time will be used in establishing the line stocker schedule for servicing the total-value flow.