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Key Concepts
Heijunka converts uneven customer pull into an even & predictable manufacturing process. Heijunka is generally used in combination with other key Toyota production system principles.
Heijunka is a core concept that bring helps bring stability to a manufacturing process.
Production Levelling Responding to fluctuating customer demand can result in increased overtime or idle time. Variable production schedules can be stressful = Unhappy workers. Fluctuations in demand are often highly amplified and delayed throughout the supply chain.
Example
Week 1 2 3 4 5 6 7 8 9 10 11 12 Total Demand 4878 3672 4536 4230 3618 4788 4464 3996 3546 4356 4536 3888 16326 / 4 = 4082 16866 / 4 = 4217
17316
4329
NUMMI facility in Fremont, USA was the first place where American automakers witnessed TPS in action outside Japan.
Hiejunka is considered one of Toyotas strengths which aided in Toyotas Global production post the oil crisis.
In Simpler terms
With progress in TPS, Toyota had reduced the changeover time from 1.5 hrs to 15 mins (in 1950s). Currently it stands at 3 mins.
Heijunka - At TKAP
Customer Variants Share of Volume
TMT
8%
Good
Lead Time
Inventory
Good not to have inventory, good to meet demand, but there really is some balance between the two. And this balance is the core of Heijunka
Good
Lesser Inventory
- Rajpandian P