Cycle Time
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Cycle time is the elapsed time to complete one unit of work from start to finish of a specific process step.
Definition
Cycle time is the elapsed time from beginning to end of a single process step for one unit of work. It measures how long it takes to complete one cycle of an operation—one part machined, one patient examined, one form processed. Cycle time is distinct from lead time (total time through all steps including waiting) and takt time (required pace based on customer demand). Understanding cycle time is essential for line balancing, staffing decisions, and capacity analysis.
Examples
An assembly station has a 45-second cycle time—that's how long from when an operator begins working on a unit until it's complete and ready for the next station. If takt time is 60 seconds, this station has 15 seconds of buffer. If takt time is 40 seconds, this station is a bottleneck.
Key Points
- Cycle time measures one step, not the whole process
- Cycle time should be compared to takt time for capacity analysis
- Variation in cycle time creates flow problems; consistency matters
- Cycle time can be reduced through process improvement without affecting lead time significantly
Common Misconceptions
Reducing cycle time automatically improves lead time. If cycle time is 5 minutes but lead time is 5 days, even halving cycle time barely affects lead time. The 5 days is mostly waiting, not processing.
Cycle time equals takt time in a balanced line. A balanced line has cycle times close to takt time, but they're different concepts. Takt time is demand-driven; cycle time is process-driven. Good design aligns them.