ABSTRACT
An initial step to setting up heijunka is starting with some sort of visual scheduling system. Planning will put the work orders in the visual work order boards on the appropriate day based on the start date. The sequencing box is typically separated into pitch intervals. Production leveling, also known as production smoothing or by its Japanese term—“Heijunka” which means “a plain, flat level,” which also means “standard level” and “change.” Pitch is the time required to supply a standard pattern of parts to a line. A key concept for level loading is production smoothing. This involves taking the production schedule and averaging it into daily or even hourly demand. Making decisions regarding space or labor based on “demonstrated capacity” is dangerous and can be extremely costly. Many companies have electronic data interchange systems where they are inextricably linked to their customer systems.
