Understand Heijunka and how to use this powerful tool to elevate your business!

By using a constant production rhythm, through Heijunka (production leveling), companies can reduce stocks, produce with quality, increase flexibility, among other benefits that we will see later.

For this, the "Just in Time" logic, basis of the Toyota Production System, should be widely applied in the production process.

In this article you will learn about:

• What is Heijunka?
• Benefits of implementing Heijunka
• How to implement Heijunka?

 What is Heijunka?

Heijunka is the leveling of the variety and quantity of items produced in a process over a period of time.

This type of leveling allows for the elimination of excessive variability in production, making it more repeatable and predictable. With this, Heijunka makes it possible to identify the quantities of raw materials and finished products that are really necessary to keep in stock, which makes it possible to reduce the number of stocked items.

In addition, using it allows you to shorten lead time, increase flexibility of response to the customer, and make production closer to actual demand.

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How to implement Heijunka?

To start using Heijunka in a company, one should start with the products that have the highest production volume and are manufactured most frequently.

Next, it is necessary to understand where the demand distortions that originate in the company's own departments come from, so that these can be eliminated and the customer becomes the true driver of production.

Another point of attention should be the "takt time", which must be defined and constantly updated in Heijunka. At Toyota, for example, it is customary to set the time interval of 6 months as a basis for the production plan.

The size of the final stock of items also needs to be established on a sound basis to meet demand and avoid overproduction.

Furthermore, in Heijunka, setup times must be reduced so that the company has the flexibility to meet new orders and changes in customer specifications. Using small batches, rather than larger ones, is also a way to meet this goal.

Another important factor for the success of Heijunka is the standardization of operations and the transition from push to pull production system.

Finally, data from Production Planning and Control (PCP) must be used and converged to keep production level.

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