Heijunka – Leveling Production Heijunka Box Leveling by Volume & Leveling by Type Examples

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“Or the production leveling. So as the demand tends to fluctuate you need to define define it tag time for keeping up with the flow of orders and yet avoid word production to help you stick with it lien has a method called heijunka and that allows you to optimize to capacity in the most appropriate way to meet the demand so in this video. We are going to look at what is heijunka half convene the production volume and for the first time. Hello.

And we ll come back to yet another video series from digital elearning. I hope you will like this video. So what is heijunka heijunka is a japanese word for labeling production. The distinguishing between leveling demand and production leveling is important because we cannot control demand.

What we can control is the rate of workload that is information raw material finished good or act. Or the actual production. Heijunka is a lean method used to leverage production and establish a continuous flow of work it is a bitch between how the customers order and how the lean company operates. It can help you react to the demand.

Changes and utilize your capacity in the best possible way. Hi. Junko helped avoid the inefficiencies of manufacturing in large lot by putting the production process closer in line with the customer demand. The objective of heijunka is to observe the sudden fluctuation in the market demand.

The flexibility that heijunka insists bring three benefit to the manufacturing. One is the predictability happens when the demand is level flexibility achieved by reducing the change. Over time. Stability.


Average production. Volume or n. Type. Over the long term.

Hi. Gingka is a workaround for uneven demand. It is a bitch between how the customer orders and how the lin company operates. It helps avoid inefficiencies in manufacturing by putting the production process frozen in line with the customer demand how to implement heijunka.

The objective of heijunka is to absorb the certain fluctuation in the market demand. The framework for any heijunka implementation should begin with tact time and end with heijunka box. That is the first step in leveling production to match the customer demand. This is what the customer buying rate is the time it takes to finish the product to meet the customer demand maxing.

The production rate to miss the customer demand help create manufacturing process that is free of bottleneck. So where do you see heijunka in the toyota house so. The heijunka is the foundation of bling. The tps that is a total production system is often rebuilt by the house.

And what is the most important part of the house the foundation and house inka. Dinka is the foundation of total production house so there are two methods of leveling production in heijunka leveling by volume and leveling by product or type so in the coming slides. We will see how can we level by volume and how can we level by a product or type. Using some examples.


Let us see what is first leveling by volume means leveling production by volume is essential leveling. It by average volume of the orders you receive to level production by volume or quantity attack. Time must be established let us look at this through some example. Suppose you receive how hats order of around 500 per week out of which you receive 200 units on monday.

Hundred routes on tuesday 50 units on wednesday. Hundred units on thursday and again 50 units on friday. So instead of using to meet the demand in sequence of the orders. The head producer will use heijunka labeling by volume to fulfill this demand.

So he will produce an average of 100 hats per day to fulfill the requirement for monday. He will keep 400 in inventory. So that an every day. He will have to produce only 100 hats.

So for monday production of 100 hats. Plus inventory of 100 hats. Will suffice his requirement for monday for tuesday. He doesn t need any inventory.

So only deliberation will be sufficient for ministry. His requirements are only 50. But he is producing hundred so 50 will be stock as inventory again for thursday. No inventory is required for fighting.


He will produce 100 bird table stock 50 is inventory. So the food inventory of friday and wednesday will add up to unity that will be you will consume on monday. Now let us see what is leveling by product or type leveling production by type allows you to level production based on average demand for each product in the portfolio and organize your work around it the principles stays. The same you create an f of each good to meet the average customer demand for product portfolio.

Let us look through this some example. Suppose we have a customer demand of 3 different types of blue red and green in the quantity that we need as per customer demand our 4 3 2. Respectively. Now as a mass producer.

They will produce these hats. In this sequence. So he will produce as blue blue blue blue. Then we ll go for red and finally green.

But a lean producer. Which will level by product or type will produce in this sequence. Blue blue red red green blue blue red red and green. That is leveling my product or typed heijunka box.

A heijunka box is a scheduling tool used to visualize the work item that needs to be completed to meet you average customer demand. It serves as a way to visualize product demand and determine the optimum sequence in the mixer product to be produced the typical heijunka box look like this gingka box is basically a combination of horizontal rows that represents the each product of product portfolio and while the vertical columns are dedicated to each day of the work each box serve as a container for scheduling work item that the team needs to complete heijunka box contains the kanban cards that indicates which type of product and in what quantity will be produced per production interval depending upon your talk time you may need to place a multiple on number of orders in each box in the toyota production system each item in the hydrangea box is a kanban card that little goes through this manufacturing person steps. It serves as if we do visualize product demand and determine the optimum sequence and the mix for product to be produced let us now see some of the benefit and drawbacks of this methodology. Suppose look i will start with benefits so flexibility to make what customer wants and when they want it presents stable demand to suppliers reduces the risk of unsold goods balance the use of labor and machine production in the lead time now let us look at some drawbacks of this methodology it limits the rapid adjustment heijunka requires industrial discipline production sequence may be disrupted due to the fluctuation in demand so let us do a quick recap of what we have learned today.


So heijunka is a lean method for leveraging production. The objective here is to observe the certain fluctuation in the market demand. It is basically a technique for reducing mura that is unevenness. Which in turn reduces muda waste and murray overburden so that is all i have on this video on heijunka.

The heart of levering production. I hope now you have a good understanding on this topic. Now you can follow this still eleni on other social media platforms like instagram youtube. Linkedin telegraph.

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