Heijunka is a Lean manufacturing concept that aims to evenly distribute production volume and mix over time. This helps convert uneven customer demand into steady and predictable manufacturing workflows. Implementing Heijunka involves leveling both production and product mix through techniques like determining the average weekly demand and producing that amount each week. Benefits include reduced lead times and inventory, as well as more stable and satisfying work for employees. Challenges to implementing Heijunka include the need for accurate demand data and larger finished goods inventory, which some see as contradictory to Lean principles. Effective Heijunka implementation provides deep breathing and calm for the manufacturing process.
Value Proposition canvas- Customer needs and pains
Heijunka Leveling
1. Heijunka
Product & Production Leveling
Module 9.3
Amy Reyner, Kweku Fleming
Mark Graban, LFM Class of ’99, Internal Lean Consultant, Honeywell
Presentation for:
ESD.60 – Lean/Six Sigma Systems
MIT Leaders for Manufacturing Program (LFM)
Summer 2004
These materials were developed as part of MIT's ESD.60 course on "Lean/Six Sigma Systems." In some cases,
the materials were produced by the lead instructor, Joel Cutcher-Gershenfeld, and in some cases by student teams
working with LFM alumni/ae. Where the materials were developed by student teams, additional inputs from the
faculty and from the technical instructor, Chris Musso, are reflected in some of the text or in an appendix