Enter Manufacturing Flow Data
Use one line per process step inside each textarea. Step 1 in every list aligns with Step 1 in the others.
Example Data Table
This sample shows a compact manufacturing stream and the kind of input structure the tool expects.
| Step | Cycle Time (sec) | Changeover (min) | Uptime (%) | Batch Size | WIP (units) | Operators | Defect (%) |
|---|---|---|---|---|---|---|---|
| Cutting | 42 | 20 | 92 | 120 | 180 | 2 | 1.2 |
| Machining | 55 | 25 | 88 | 120 | 140 | 3 | 2.4 |
| Assembly | 68 | 15 | 90 | 120 | 100 | 4 | 1.8 |
| Inspection | 35 | 10 | 96 | 120 | 60 | 2 | 0.9 |
| Packing | 28 | 8 | 97 | 120 | 30 | 2 | 0.5 |
Formula Used
Takt Time = Available Time per Day ÷ Customer Demand per Day
Effective Cycle Time = Cycle Time ÷ (Uptime % ÷ 100)
Queue Time per Step = (WIP Units ÷ Daily Demand) × Available Minutes per Day
Good Capacity = [(Available Time × Uptime × Safety Factor) ÷ Cycle Time] × Yield
Yield = 1 − (Defect Rate ÷ 100)
RTY = Yield₁ × Yield₂ × Yield₃ × ... × Yieldₙ
Lead Time = Queue Time + Effective Processing + Changeover + Transport Delay + Information Delay
PCE = (Value-Added Time ÷ Total Lead Time) × 100
How to Use This Tool
- Enter available minutes per day, customer demand, transport delay, information delay, and the safety factor.
- Add each process step on its own line in the process names field.
- For every other textarea, keep the line order aligned with the process names.
- Enter cycle times in seconds, changeovers in minutes, and uptime and defect values as percentages.
- Provide batch size, WIP inventory, and operator count for each step.
- Submit the form to generate takt time, lead time, bottleneck analysis, PCE, RTY, and detailed step metrics.
- Use the graph to compare cycle behavior, capacity, and WIP across the stream.
- Download CSV for spreadsheet work or PDF for reports and improvement meetings.
FAQs
1) What does this tool measure?
It measures core value stream mapping indicators such as takt time, queue delay, process cycle efficiency, bottlenecks, rolled throughput yield, capacity, and total lead time.
2) Why is takt time important?
Takt time links customer demand with production rhythm. When effective cycle time exceeds takt, the step may struggle to meet daily demand consistently.
3) What is the bottleneck in this report?
The bottleneck is the step with the lowest good daily capacity after uptime, defects, and safety factor are considered. It limits the stream’s reliable output.
4) How is queue time estimated?
Queue time is estimated from inventory and demand. The tool divides WIP by daily demand, then converts that delay into minutes using available daily operating time.
5) What does rolled throughput yield mean?
Rolled throughput yield combines every step’s yield into one measure. It estimates the chance that a unit passes through the full stream without defects.
6) Why use a safety factor?
A safety factor reduces theoretical capacity to a more realistic planning level. It helps account for variation, micro-stoppages, and normal operating uncertainty.
7) What does process cycle efficiency show?
Process cycle efficiency compares value-added time with full lead time. Low PCE usually indicates large waiting, transport, information delay, or changeover waste.
8) Can I use this for future-state mapping?
Yes. Enter target cycle times, lower WIP, better uptime, or smaller delays to model improvement scenarios and compare future-state performance against current-state results.