Solutions for Lean Manufacturing

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Picture for category Heijunka


Heijunka is the Japanese term for production leveling. Thanks to a detailed planning in the production processes, focusing on small quantities of materials, it guarantees safety in production and commercial terms, avoiding changes in both demand and supply, with consequent imbalances and losses, both in purchases and sales (or no sales) . The handling and storage of goods is improved, waste is avoided and a closer relationship with suppliers is established, as well as optimizing the work of staff and working hours.

The intervention is based on two specific segments:

Leveling production by volume

The "leveled production volume" is given by the uniform distribution of production in a given period of time: the average of the demand in a given period of time is assessed, having a minimum stock available to cover any higher requests, thus avoiding a excessive supply. The leveled production volume depends on the: "leveled production variety"

Leveling production by product mix

The "leveled production variety" is the uniform distribution of the mix / production variety in a given period of time: organizing the production in batches to maintain the same level of productivity in different departments, avoiding that a single product exceeds the average production of the others ... You don't run where you don't need it but you "pull" the entire production flow.



How to make a Heijunka blackboard


- Decide the number of Rows (products) and the number of Positions (time unit to divide the working day)


- Decide on the format and color of the Systemboxes . Using alternating colors better displays the positions.




The distinction between the various tempono units becomes more visible if Systembox of different, alternating colors are used.


Frontal view Side view
Time subdivision Timepieces



Standard solution Diagonal Solution for a better
Code No. recognition