Cycle Time

Accurate cycle time measurement requires observing the actual production process, not relying on engineering estimates or machine specifications. Start by defining the start and end points of the cycle clearly — for a CNC machining operation, does cycle time include loading and unloading, or only the machining cut? The definition should match your purpose: capacity planning needs the full cycle including load/unload, while process optimization may focus on individual elements. Use a stopwatch or automatic data collection to time at least 10 consecutive cycles, recording each observation. Calculate the average, but also note the range and standard deviation — high variability in cycle time is itself a problem that needs addressing. For automated equipment, many modern machines can report cycle time directly via their control systems. For manual operations, time studies using the work measurement methodology provide reliable data. Record cycle times at different points during the shift to capture fatigue effects, and across different operators to understand skill-based variation.

Reducing cycle time multiplies manufacturing capacity without capital investment, making it one of the highest-ROI improvement activities. Start by breaking the cycle into individual elements and categorizing each as value-adding (the customer would pay for it), necessary non-value-adding (required by the process but not valued by the customer, such as loading/unloading), or pure waste (waiting, searching, rework). Eliminate waste elements first. Common cycle time reduction strategies include: paralleling operations (performing two activities simultaneously rather than sequentially), improving tooling (sharper or more durable tools reduce machining time), reducing changeover content (SMED techniques move setup activities outside the cycle), minimizing material handling (bringing materials closer to the point of use), and addressing variation (standardized work ensures every operator follows the fastest proven method). Even a 10% cycle time reduction on a bottleneck operation can increase total line output by 10% — the leverage is enormous.

Accurate cycle time data is the bedrock of realistic production scheduling. If your schedule assumes a 2-minute cycle time but the real average is 2.5 minutes, every order will be delivered late — and the gap worsens as orders accumulate. When building a production schedule, use the actual measured cycle time (not the theoretical best case) and include a realistic efficiency factor. For digital scheduling in LinePlanner, cycle time data feeds directly into capacity calculations: if a product requires 5 minutes of cycle time and a shift has 420 available minutes with 85% OEE, that line can produce 420 × 0.85 / 5 = 71 units per shift. Cycle time also determines sequencing decisions: products with long cycle times should be scheduled to avoid bunching at bottleneck operations. Monitoring actual vs. planned cycle times during production execution highlights problems in real time, enabling supervisors to take corrective action before deliveries are impacted.