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Level Out the

Workload- Chapter 10
1

Muda
Waste

Mura Muri
Unevenness Overburtden

Waste
2

Muri
Mura

Muda

Waste
3

1
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Leveling production and schedule

Take the total volume of orders in

a period and level them out so that
the same amount and mi are being
made each day
Heijunka
4

Monday

Tuesday

Wednesday C/O

Thursday

Friday C/O

Small Engine
Medium Engine

Large Engine

Traditional Production
5

Customers do not usually buy

products predictably
There is a risk of unsold goods
The use of resources is
unbalanced
Places an uneven demand on
upstream processes.

Problems
6

2
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Monday

Tuesday

Wednesday

Thursday

Friday

Mixed Model Production - Leveled

7

Eliminate changeover
Create flow racks of parts for each
engine
Mount tools over production line
Create flexible size pallets

Achieve Leveling
8

Flexibility to make what the customer

wants when they want it
Reduced risk of unsold goods
Balanced use of labor and machines
Smoothed demand on upstream
processes and the plants suppliers

Benefits of Leveling
9

3
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Situation: significant fluctuations

in customer demand
Solution: small inventory of
finished goods
Production:
Build to order
Build for stock

Inventorys Role in Leveling

10

Fit customer demand into a

leveled schedule
Established times for delivering
different types of services

Heijunka in Service Operations

11

Build to order
delivered immediately
Seasonal product
Built throughout the year
Accumulated in seasonal inventory buffer
Safety stock
Buffer against unexpectedly high demand
Buffer stock
Cushion against factory downtime
Case Study Four inventories
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