Heijunka Case Study

Good Essays
4. Heijunka:
It is the practice followed by industries to smoothen or sequence their production line up.
The main purpose of Heijunka is to captivate sudden demand fluctuations in market by producing several different models in small batches on the very same line.
It is a main part of “one-piece flow” system.

This practice also removes mudas (waste/ non -value -added activities) and standardising work becomes easier. A good sequencing practice is one which reduces the need for labour at the line side of production.

For better benefits from fixed investments in lines, the use of resources such as (factories, shop floor, machinery) must be maximised by improving in their time plan, so that higher production rates can be achieved with
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This assists stability and standardisation in process of production.

The secondary objective of Heijunka is to assemble different models on the same line while eliminating Mudas by standardised work.

The main application of Heijunka is that customer demand is main criteria followed to decide the amount of goods that are to be produced. It distributes and balances production over all other available means, instead than allowing dedicated resources to suffer from sudden demand fluctuations.

Different to the traditional idea, it is much easier to balance workstations when the lines are multi-mode. Because by working more on one product on one stage, less work will be required on the next stage: basic tasks are increased, sorted out and therefore more easily divided into basic units.

By multiplying the tasks, and dispensing them in a better manner, and by standardising them by carefully-studied smoothing, better utilization of the working time is done thus increasing the value.

5. Waste management (Muda, Mura and
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Waiting; the act of waiting for a machine to finish, for product to arrive, or any other cause.
5. Overproduction; Over producing product beyond what the customer has ordered.
6. Over-processing; conducting operations beyond those that customer requires.
7. Defects; product rejects and rework within your processes.

Mura: the waste of unevenness or inconsistency.

Many of the above-mentioned wastes that we observed are caused by Mura.
The causes of Mura can be removed by implementing lean tools such as JIT, Heijunka, Kanban and other methods which permits smoothing the flow of production process.

If we fail in smoothing the processes we put unfair amount of demands on processes causing the formation of inventory and many other wastes.

One very apparent example is the production processes where the supervisor is measured based on monthly production.
The department completes most of its work in the final week of the month to meet targets, using components and parts not actually required.
Because of this the first week of the next month is then sluggish due to shortage in components and other resources.

Muri: the waste of Overburden

Causes of Muri
 Working on processes you are not trained in
 Poorly laid out work

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