Cycle Time
Cycle time measures how long a single process step actually takes -- from start to finished result. It is the foundation of every process analysis.
Cycle time describes the actual duration of a work step or a complete run. Unlike takt time, which is a target value, cycle time is a measured value taken directly from the process.
There are different definitions depending on context: In unit production, it's the time from start to end of a work operation. In series production, it's the time between two consecutive finished parts.
Cycle time naturally varies from cycle to cycle. That's why it's important to measure multiple cycles and look at both the average and the variation. High variation indicates an unstable process.
Reducing cycle time is one of the most powerful levers in process optimization: Every second saved per cycle multiplies with the number of units and adds up to enormous savings.
Formula
Cycle Time = Processing Time + Ancillary Time + Waiting Time within the Process Step
Practical Example
At an assembly station, 25 assemblies are completed in 30 minutes. The average cycle time is 72 seconds. The takt time is 60 seconds. The process is 12 seconds too slow -- a bottleneck that can be resolved by optimizing hand movements or improving material staging.
How Leanshift Helps
The stopwatch function in Leanshift precisely captures cycle times across multiple runs. It automatically detects variations and calculates the stable current state as a basis for improvements.
Frequently Asked Questions
How do you measure cycle time correctly?
Measure at least 10-15 consecutive cycles, mark outliers, calculate the average and variation. Important: Always measure at the actual process, never derive from standard times.
What is the difference between cycle time and lead time?
Cycle time measures a single process step. Lead time encompasses the entire timespan from raw material to finished product -- including all waiting and storage times between steps.
Why does cycle time vary?
Common causes: Different operator experience levels, material deviations, tool wear, lack of standardization, or ergonomic issues.
Related Terms
OEE (Overall Equipment Effectiveness)
OEE is the key metric for machine and equipment productivity. It combines availability, performance, and quality into a single percentage value.
Takt Time
Takt time is the pace at which a product must be completed to meet customer demand. It is determined by the market, not by the machine.
Lead Time
Lead time measures the total duration from order receipt to delivery -- including all waiting, storage, and transport times. It determines delivery capability.