A Heijunka board, also known as a load leveling board, is a visual management tool used in lean manufacturing to achieve a consistent and efficient production schedule. The term "Heijunka" comes from the Japanese words "hei" (平), meaning "level," and "junka" (順化), meaning "to smooth" or "to level out."
Purpose of a Heijunka Board
The primary purpose of a Heijunka board is to help balance production by leveling the workload and smoothing out fluctuations in customer demand. This is achieved by visually organizing and sequencing production orders in a way that allows for a consistent flow of work through the production process.
Components of a Heijunka Board
A typical Heijunka board consists of the following components:
Customer Demand: This is represented on the board by the actual customer orders or the demand forecast for a specific period, such as a day, week, or month.
Production Sequence: The production sequence is determined based on the customer demand and the available production capacity. It shows the order in which products will be produced to meet customer requirements.
Work Orders: Work orders or production cards represent individual products or batches that need to be produced. These are placed on the board in the sequence determined by the production plan.
Time Period: The Heijunka board is typically divided into time periods, such as shifts or days, to represent the production schedule over a specific period.
Capacity Planning: Capacity planning information, such as available production hours or machine capacity, may also be included on the board to ensure that the production plan is feasible.
How a Heijunka Board Works
The Heijunka board works by visually representing the production schedule and allowing production teams to see at a glance what needs to be produced and when. By leveling the workload and sequencing production orders, the board helps to avoid overproduction, reduce lead times, and improve overall efficiency.
Benefits of a Heijunka Board
Some of the key benefits of using a Heijunka board include:
Reduced Waste: By leveling production and avoiding overproduction, waste is reduced, including excess inventory, overprocessing, and waiting time.
Improved Efficiency: A Heijunka board helps to improve production efficiency by ensuring that resources are utilized effectively and production flows smoothly.
Better Customer Service: By matching production to customer demand, a Heijunka board helps to improve on-time delivery and customer satisfaction.
Visual Management: The board provides a visual representation of the production schedule, making it easy for teams to understand and follow the plan.
A Heijunka board is a valuable tool for achieving a consistent and efficient production schedule in lean manufacturing. By leveling the workload and smoothing out fluctuations in customer demand, the board helps to reduce waste, improve efficiency, and enhance customer service.