Workstation Cycle Time: Definition, Calculation, and Importance

Workstation cycle time refers to the maximum duration required to complete a job at a specific workstation. It plays a crucial role in production line balancing, which aims to optimize workflow and minimize idle time.

Key Facts

  1. Definition: The workstation cycle time is the maximum duration it takes for a job to be completed at each workstation.
  2. Calculation: The cycle time can be calculated by dividing the required product units by the production time available in a day.
  3. Types of cycle time: There are two types of cycle time: effective cycle time and equipment cycle time. Effective cycle time includes all activities that support the manufacturing process, while equipment cycle time focuses solely on the core processing time.
  4. Typical vs. ideal cycle time: Typical cycle time is the average time achieved under normal operating conditions, while ideal cycle time represents the theoretical minimum time required to process one unit.
  5. Importance: Cycle time is an important manufacturing KPI that helps measure the efficiency of production processes, identify bottlenecks, and optimize production planning and scheduling.
  6. Benefits: Tracking cycle times can lead to increased efficiency, informed shop floor workers, better production scheduling, higher production rates, reduced lead times, and improved customer satisfaction.
  7. Cycle time loss: Cycle time loss occurs when equipment runs slower than ideal or when small stops occur in the cycle. It is measured by subtracting the ideal cycle time from the total run time of the process.
  8. Causes of cycle time loss: Common causes include machine downtime, inefficient processes, raw material shortages, human factors, bottlenecks, quality issues, and poor workflow design.
  9. Reducing cycle times: Cycle times can be reduced by streamlining material management, automating repetitive processes, adopting lean manufacturing principles, and optimizing processes with manufacturing ERP software.

Calculation

The cycle time can be calculated by dividing the required product units by the production time available in a day. This calculation helps determine the number of workstations needed to achieve the desired production rate.

Types of Cycle Time

There are two primary types of cycle time:

Effective Cycle Time

Encompasses all activities that support the manufacturing process, including preparatory and concluding steps like loading and unloading materials. It provides a comprehensive view of the process time.

Equipment Cycle Time

Focuses solely on the time a unit is actively being processed, excluding any preparatory or concluding activities. It is essential for analyzing the efficiency of the core manufacturing process itself.

Typical vs. Ideal Cycle Time

Typical Cycle Time

Represents the average time achieved under normal operating conditions. It is a realistic measure for planning and benchmarking, reflecting actual operational performance.

Ideal Cycle Time

Represents the theoretical minimum time required to process one unit, assuming optimal conditions without any delays or inefficiencies. It serves as a target for process improvement initiatives.

Importance of Cycle Time

Cycle time is a critical manufacturing KPI that helps measure the efficiency of production processes and identify bottlenecks. It plays a vital role in:

Increased Efficiency

Tracking cycle times helps pinpoint inefficiencies and non-value-adding activities, enabling continuous improvement and optimization of production processes.

Informed Shop Floor Workers

A defined cycle time provides shop floor team members with clear expectations regarding process times, enhancing productivity and reducing variability.

Better Production Scheduling

Calculating average processing times allows for accurate production schedules based on realistic time estimates.

Higher Production Rates

Reducing cycle time often leads to increased production rates without compromising product quality.

Reduced Lead Times

Improved processing times result in shorter lead times, enhancing customer responsiveness and satisfaction.

Improved Customer Satisfaction

Shorter lead times and the ability to quickly respond to changing customer demand inevitably lead to greater customer satisfaction.

Cycle Time Loss

Cycle time loss occurs when equipment runs slower than ideal or when small stops that do not qualify as downtime occur in the cycle. It is measured by subtracting the ideal cycle time from the total run time of the process.

Causes of Cycle Time Loss

Common causes of cycle time loss include:

Machine Downtime

Breakdowns or unplanned maintenance can significantly slow down production.

Inefficient Processes

Unoptimized processes can involve unnecessary steps and cause delays in production.

Raw Material Shortages

When the necessary materials do not reach the shop floor at the right time, waiting time can increase cycle time.

Human Factors

The aptitude level or agility of the operator can substantially affect processing times.

Bottlenecks

If a production step is bottlenecking, it may slow down production in all the processes downstream from the bottleneck.

Quality Issues

Time spent identifying or reworking quality issues adds to the cycle time. These issues may stem from sub-par materials or employee errors.

Poor Workflow Design

An inefficient shop floor layout and poorly conceived production routings can lead to unnecessary movement and an increase in process times.

Reducing Cycle Times

Cycle times can be reduced by:

Streamlining Material Management

Efficient management of raw materials is crucial to minimize waiting time in production. Optimizing the internal supply chain ensures the timely availability of raw materials on the shop floor.

Automating Repetitive Processes

Manufacturing automation plays a significant role in reducing processing times. By automating repetitive tasks and processes, manufacturers can significantly reduce the period of time spent on each production cycle.

Adopting Lean Manufacturing Principles

Lean manufacturing techniques, such as kanban, help streamline production and reduce waste, including excess cycle time loss. Kanban systems can be particularly effective in managing workflows, reducing waiting times, and ensuring that production aligns with customer demand and timelines.

Optimizing Processes with Manufacturing ERP Software

MRP or manufacturing ERP software can be transformative in reducing cycle time loss. By tracking cycle times in MRP systems, manufacturers can gain invaluable insights into their production processes, enabling them to eliminate the root causes of cycle time loss.

Conclusion

Workstation cycle time is a critical factor in production line balancing and overall manufacturing efficiency. By understanding the concept of cycle time, its types, and the factors that affect it, manufacturers can optimize their production processes, reduce cycle time loss, and improve overall productivity.

References

  1. What is Production Line Balancing? – Corning Data
  2. What is Cycle Time in the Manufacturing Process? – Blog for Manufacturers and Distributors
  3. Line Balancing with R. Understanding Takt Time, Cycle Time and Lead Time – Roberto Salazar | Analytics Vidhya | Medium

FAQs

Workstation Cycle Time: Definition, Calculation, and Importance

Definition

Workstation cycle time refers to the maximum duration required to complete a job at a specific workstation. It plays a crucial role in production line balancing, which aims to optimize workflow and minimize idle time.

Calculation

The cycle time can be calculated by dividing the required product units by the production time available in a day. This calculation helps determine the number of workstations needed to achieve the desired production rate.

Types of Cycle Time