What is heijunka?
Heijunka is a Lean method for reducing the unevenness in a production process and minimizing the chance of overburden. The term Heijunka comes from Japanese and literally means leveling. It can help you react to demand changes and utilize your capacity in the best possible way.
What is heijunka and how does it work?
Heijunka (hi-JUNE-kuh) is a Japanese word for leveling. It is part of the lean methodology of process improvement that helps organizations match unpredictable customer demand patterns and eliminate manufacturing waste by leveling the type and quantity of production output over a fixed period of time.
What are the key principle of heijunka?
The heijunka principle simply allows businesses to respond to changes in customer demand by establishing a standard or leveled flow of work.
What is heijunka in TPS?
Heijunka (pronounced hi-JUNE-kuh) is defined as a technique for reducing unevenness in a production cycle, which in turn reduces waste. It’s a Japanese term that means “leveling” and is a key lean manufacturing method first used by the Toyota Production System (TPS) to develop production efficiency.
Why do we need Heijunka?
Heijunka is the process of leveling the type and amount of production over a set period of time. The goal is to iron out issues like overproduction, or batching — which has the added benefit of minimizing waste, reducing labor, maximizing inventory space, and reducing production lead time.
How do you implement Heijunka?
Why and How to implement Heijunka
- Calculate tack time: (seg /min /hr) Tack Time = Production time available / total number required.
- Calculate pitch of each product: (high volume = 12 and 30 min)
- Establish the production rate:
- Creating Heijunka box:
How do you implement heijunka?
Who invented heijunka?
Toyota
A heijunka box is a visual scheduling tool of used in heijunka, a concept originally created by Toyota for achieving a smoother production flow.
Why do we need heijunka?
How do you calculate heijunka?
The interval is calculated as follows: sum up the process times for all products in the family for the specific workstation for a certain interval, for instance a week. Take the total production time available in the week, and subtract the total process time. The result is the time which is left for changeovers.