Written by Cycle time refers to the period it takes for a process to complete one unit of production. At Tork Mekatronik, we continuously strive to enhance productivity and reduce cycle time in our manufacturing processes. In this article, we will detail our cycle time improvement process and share a successful project involving a laser marking station.
Current State Analysis
Before initiating cycle time improvement efforts, we conduct a thorough analysis of the current state. This involves recording all steps and times within the production process. Analyzing the current state is critical for identifying improvement opportunities.
Components of Cycle Time
Cycle time comprises machine time and downtime. Detailed analysis of both components is essential to optimize the total cycle time.
Machine Time Analysis
Machine time encompasses the automatic operations in the production process. At Tork Mekatronik, we use our method to monitor machine time with millisecond precision. This method allows us to measure and analyze machine times with exceptional accuracy. We use Gantt charts to visually plan and track these times. Gantt charts provide crucial insights for optimizing machine utilization and minimizing delays.
Identifying Lost Time
After detailed analysis of machine times, we identify lost time. Lost time includes delays, waiting periods, or unnecessary operations that reduce efficiency. We work meticulously to eliminate these inefficiencies.
Developing Improvement Projects
We develop various improvement projects to eliminate identified lost time. These projects may involve process improvement, automation, workflow reorganization, and software optimizations. Each project targets specific sources of lost time and aims to enhance production efficiency.
Case Study: Cycle Time Improvement in Laser Marking Station
Project Initiation
Our client operated production lines using laser marking stations with an annual production volume of 2,000,000 units. These stations operated with varying times depending on the product’s position and were bottlenecks in both lines. The preceding machines had shorter cycle times.
Initially, the client requested us to install two additional laser marking stations for the existing two lines. However, Tork Mekatronik recommended improving the cycle time of the existing stations instead. The client welcomed this suggestion, and we commenced the project.
Current State Analysis
We first analyzed the current state of the laser marking stations. We meticulously measured the machine times for both lines, using our method to control machine times with millisecond precision and employing Gantt charts for visual analysis.
Identifying Lost Time
The analysis revealed various sources of lost time in the laser marking stations, including centering delays, data matrix code preparation time, and stopper delays. We particularly optimized the total time by overlapping the data matrix code preparation with the centering process.
Developing Improvement Projects
To eliminate lost time, we developed several improvement projects. First, we reorganized the workflow to reduce waiting times and increased automation levels. We also minimized machine setup times through software optimizations and integrated more precise and faster positioning systems. Additionally, we optimized the total time by overlapping the data matrix code preparation with the centering process.
Results and Benefits
The improvements resulted in a 25% reduction in cycle time for the laser marking stations, decreasing from 19 seconds to 14 seconds. This enhancement increased overall production line efficiency and eliminated bottlenecks, leading to a smoother production process. The benefits realized by our client included:
- Investment Cost Savings: The client avoided a 95% potential cost increase by not investing in new laser marking stations.
- Time Savings: The 10-12 week waiting period for new machine production was eliminated.
- Increased Efficiency: Bottlenecks were eliminated, resulting in a more seamless and efficient production process.
- Cost Reduction: Improved cycle time led to lower production costs.
- Customer Satisfaction: A faster and more efficient production process increased customer satisfaction.
Conclusion
Cycle time improvement is critical for enhancing productivity and reducing costs in production processes. At Tork Mekatronik, we optimize cycle times through detailed analyses and improvement projects, providing our clients with faster and more efficient manufacturing solutions. By controlling machine times with millisecond precision using our methods, we continue to maximize the efficiency of our production processes.