Lean processes strive to achieve a constant rate of flow referred to
as the ëtaktí time. The takt time is the rate of production needed
during a shift to exactly meet the customer demand. During our
work at five plants, lines without variable flow ran at 60% operator
activity whereas constant takt lines ran at 80%. On this evidence, by
converting a line from variable to constant flow and introducing
standard operations, there is potential to require 25% fewer staff.