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Level Out the Workload (Heijunka)

Putting Leveling and Flow Together-A Tough Sell

Every business would like to have a consistent volume over time so there is a consistent and predictable workload. That is an easy sell in concept. But if your sales department does not behave like Toyota Sales by cooperating to […]

Heijunka in Service Operations

Leveling out a work schedule is easier in high-volume manufacturing than in typically lower-volume service environments. How do you level schedules in a service operation where service providers are responding to customers and the lead times on service work vary […]

“Build to Order” Yet Heijunka

Cho’s quote at the opening of this chapter suggested customers may have to wait a little longer if they want to order a vehicle specially built for them. He is not willing to sacrifice the quality and efficiency benefits of […]

Leveling the Schedule-Inventory’s Role

Leveling the schedule has profound benefits throughout the value stream, including giving you the ability to plan every detail of production meticulously and standardizing work practices. If you visit a Toyota plant or a Toyota supplier, you will see the […]

Heijunka-Leveling Production and Schedules

Heijunka is the leveling of production by both volume and product mix. It does not build products according to the actual flow of customer orders, which can swing up and down wildly, but takes the total volume of orders in […]