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Digital dashboards for takt time flow with takt time counter and stop time log.
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When the agricultural machinery manufacturer Väderstad implemented takt-based flow in Boards on Fire, the company took an important step toward the production of the future. The new structure has created a smoother pace, increased efficiency, and a capacity of up to 20 machines per week.
The family-owned company Väderstad was founded in 1962 on an estate in Väderstad and has since grown to become one of the world’s leading players in soil cultivation, sowing, and precision seeding. To streamline its assembly process, Väderstad has implemented a takt-based flow—a structured working method visualized in the Boards on Fire system.
This smart approach divides the assembly process into nine clearly defined stations, with each step set to a fixed takt time of two hours and 20 minutes. This means that two machines are produced in sequence, followed by an empty takt to give operators time to prepare for the next cycle. With this structure, Väderstad can produce up to 20 machines per week! Thanks to the takt-based flow, production has become smoother and more efficient, while it is also easier to keep track of every part of the process.
One of the biggest advantages of Boards on Fire, according to Johan Elmenius, who is responsible for its implementation at Väderstad, is its simplicity and user-friendliness.
– The system is extremely easy to set up and get started with, and it doesn’t require any advanced IT infrastructure, says Johan Elmenius, Head of Väderstad Production System.
Boards on Fire can be operated through a web browser on a standard TV screen, making it easy for operators to monitor and control production even without a technical background.
– We were able to get up and running quickly with the system to manage production, he adds.
To ensure that every step in production follows the plan, Väderstad has implemented Boards on Fire. The system monitors the progress of each station and clearly displays on large takt boards whether production is keeping pace or if deviations occur. The boards, connected to Väderstad’s business system, synchronize production data and material management in real time, making the entire process transparent and easy to follow.
Väderstad uses takt windows, meaning each takt is counted down with a 17 percent buffer, providing flexibility to manage potential delays. This creates an additional cushion to ensure that all parts of production maintain the correct pace.
Johan also emphasizes how Boards on Fire has created greater clarity in the production process.
"It has given us exceptional clarity. Everyone in the organization now shares a common understanding of the production flow, which makes it easy to identify and address deviations," he explains.
The system has also improved collaboration between departments, particularly regarding material supply, which is now better synchronized with production. The takt clocks establish a clear work rhythm and standardize working times across the production hall, reducing the risk of delays and enhancing efficiency.
The takt boards have become a central part of Väderstad’s daily production. All nine stations are closely monitored, and the boards clearly indicate whether the pace is being maintained or if intervention is required. Operators can see when and how materials need to be replenished and track any deviations in real time. This enables problems to be addressed quickly, allowing production to continue smoothly without major interruptions.
When a disruption occurs, such as a station failing to meet the takt time, it is immediately displayed on the takt board. Operators follow a clear escalation routine, and the system shows exactly where the disruption happened. This allows additional resources to be quickly allocated if a station falls behind. If the cause is material supply, it is also indicated on the board, and corrective actions are taken immediately. This ensures that production quickly returns to normal levels.
In summary, by implementing takt-based flow, Väderstad has achieved greater clarity, efficiency, and control over its production. The system has made it easier to manage disruptions and ensures that all parts of production operate according to plan. Johan Elmenius sees significant potential for the system and believes it can be further developed to optimize production even more.
"It is a system that is both powerful and easy to use, and I believe more companies could benefit from this type of solution to improve their processes," concludes Johan.
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