This simulation shows the Lean concepts of Takt Time and Line Balancing.
http://thebigleansimulationlibrary.com/
In the first scenario, we are manufacturing a sign that says “TAKT!”. Customer demand is 1.25 signs/second. Note that while we produce 5 characters for the sign, we only have 4 machines. Also note that “T” is required twice and that different letters take different amounts of time to produce.
Currently, each machine produces a different character. The characters go into the Assembly queue. Once there are one each of T-A-K-T-! in the queue, the assembly station builds the sign in 1 second and the completed sign is sent down the conveyor.
When then run the model. Note that because two T characters are required, that machine cannot keep up. The ! character is the quickest to produced, so we get an excess of them in the queues, as shown below. We are not able to meet customer demand and have excessive queues. We will run out of space to store letters if we keep producing. This shows excessive Work In Process (WIP).
In the second scenario, we present a better solution where the workload on the machines is balanced, As a result, we do not build up excess inventory and are able to keep up with customer demand.
Lean and Lean Six Sigma (LSS) trainers can present this models as part of their courses. Consultants can also use it to show managers and executives concepts quickly to help sell their ideas.
