Cycle Time is the total elapsed time from the beginning to the end of a specific process, operation, or workflow. In manufacturing, it represents how long it takes to complete one unit of production through a particular process or how long it takes to transform raw materials into a finished product. Unlike processing time (which measures only the value-adding work), cycle time includes all elements: setup, processing, inspection, waiting, and any interruptions that occur during the production cycle.
Understanding and measuring cycle time is fundamental to improving manufacturing performance. At the machine level, cycle time tells you how quickly equipment can produce each part, which directly determines capacity and throughput. For example, if a machining operation has a cycle time of 5 minutes, that work centre can theoretically produce 12 parts per hour. At the order level, cycle time measures the total time from when a customer places an order until the finished product is ready to ship, which determines your lead times and responsiveness to customers.
Several factors influence cycle time. Setup or changeover time adds to cycle time when switching between different products. Queue time (waiting for the next operation) often represents the largest component in total manufacturing cycle time, even though it adds no value. Processing time is the actual work being performed, whilst move time accounts for transportation between operations. Inspection, rework, and machine breakdowns all extend cycle time beyond the theoretical minimum.
Reducing cycle time delivers multiple benefits. Shorter cycle times mean faster response to customer orders, less work-in-progress inventory tying up capital, quicker cash conversion, and greater agility to respond to changes. Manufacturers reduce cycle time through various methods: eliminating non-value-adding activities, reducing setup times through SMED (Single-Minute Exchange of Die) techniques, balancing workload across resources, improving equipment reliability, and streamlining material flow to reduce queue times.
Modern MES and ERP systems automatically track cycle times by recording start and stop times for operations, calculating averages, and highlighting variances from standards. This data helps identify which processes are running efficiently and which need improvement. Comparing actual cycle times against standard times also reveals capacity constraints and helps planners create more accurate production schedules. For continuous improvement initiatives, cycle time serves as a key performance metric, with teams working systematically to eliminate the waste that extends time without adding value.
