Cycle time is how long a station actually takes per unit. Comparing it to takt reveals bottlenecks — any station slower than takt caps the whole line’s output.
The example
3,000 sec, 50 units → 60 sec.
| A | B | |
|---|---|---|
| 1 | Item | Value |
| 2 | Cycle (3000/50) | 60 |
| 3 | vs takt 65 | OK |
The formula
The formula:
How it works
How it works:
- Cycle time = run time ÷ units produced — the actual seconds per unit at a station.
- Compare each station to takt: cycle ≤ takt keeps up; cycle > takt is a bottleneck.
- The line’s real output is set by the slowest station (the longest cycle).
- Line balance efficiency = total work content ÷ (stations × bottleneck cycle).
The bottleneck is the whole line’s pace. A six-station line where five hit 55 seconds and one takes 75 produces at 75-second cadence, not 55 — the slowest station governs. Charting each station’s cycle against takt (a bar chart with a takt line) instantly shows which station to improve, and by how much, to unblock throughput.
Try it: interactive demo
Run time, units, takt.
Variations
Bottleneck flag
Slower than takt:
Line output rate
Slowest station:
Balance efficiency
How balanced:
Pitfalls & errors
Slowest station wins. The line runs at the longest cycle, not the average.
Cycle vs takt. Cycle is actual; takt is required — compare them.
Consistent units. Keep run time and takt in the same time unit.
Practice workbook
Frequently asked questions
How do I calculate cycle time in Excel?
How do I find a line bottleneck?
What sets the line's output rate?
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