Heijunka (Production Leveling), Product Leveling, Production Leveling

Heijunka (Production Leveling)

The distribution of production volume & mix evenly over time

• Sequencing of production, production smoothing, or “level production”
• Converts uneven Customer Pull into even & predictable manufacturing process
• A core concept that helps bring stability to a manufacturing process

Reasons for implementing Heijunka

• Product Leveling
• Production Leveling

Product Leveling

Large batches of the same product may reduce set-up times & changeovers, but usually result in:

• Long lead times,
• Swelling inventories,
• Greater opportunities for defects,
• Excessive idle time and/or overtime.

An even mix of products is critical to avoiding these impacts

Production Leveling

• Fluctuations in demand are often highly amplified & delayed throughout the supply chain
• Responding to fluctuating customer demand can results in increased overtime or idle time. 
• Variable production schedules can be stressful = Unhappy workers. 
• A more level production volume eases these complications

Heijunka is the deep breathing exercise of Lean