LEVEL OUT THE WORKLOAD: HEIJUNKA

Heijunka is a system of production-leveling that

produces the right product mix as demanded by
the customer by making optimal utilization of the
available capacity
 WHY IMPLEMENT HEIJUNKA
 Many companies wants to produce what customers
want and when they want

 They follow build-to-order approach

 However customer orders creates uneven

production schedule becomes uneven

 This eventually leads to large amount of inventory ,

hidden problems and poorer quality

 And here arises the need for creating balanced lean

workflow “Heijunka”
3 M’s (MUDA, MURI, MURA)
3 M’s (MUDA, MURI, MURA)
ACHIEVING HEIJUNKA
LEVELING OUT THE PRODUCTION

Leveling
By

Quantity Product
 CONCLUSION

Heijunka is fundamental to eliminating

mura, which is fundamental to
eliminating muri and muda
Kaizen (改善) is the Sino-Japanese word for "improvement". In business, kaizen refers to
activities that continuously improve all functions and involve all employees from the CEO
to the assembly line workers.
Kaizen 5S framework

A 5S framework is a critical part of the Kaizen system and establishes an ideal physical
workplace. The 5Ses focus on creating visual order, organization, cleanliness and
standardization to improve profitability, efficiency, service and safety. Below are the
original Japanese 5Ses and their common English translations.

Seiri/Sort (organize) -- Separate necessary workplace items from unnecessary ones and
remove unnecessary items.

Seiton/Set in order (create orderliness) -- Arrange items to allow for easy access in the way
that makes the most sense for work.

Seiso/Shine (cleanliness) -- Keep the workspace clean and tidy.

Seiketsu/Standardize (standardized cleaning) -- Systematize workplace cleanup best

practices.

Shitsuke/Sustain (discipline) -- Keep the effort going.

 Benefits of kaizen

 Empower employees, Enrich work experience and bring out the best in each
person.

 Promote personal growth of employees and company.

 Improve quality, safety, cost structure, delivery environment, throughput

and customer service /satisfaction.

 Provide guidance for employees and serve as a barometer for leadership.