How do you use heijunka or production leveling to balance demand and capacity in PDCA and jidoka systems?

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Heijunka, or production leveling, is a lean tool that helps you smooth out the flow of work and reduce waste, variation, and overproduction. It is based on the idea of producing what the customer needs, when they need it, and in the right quantity and quality. In this article, you will learn how to use heijunka to balance demand and capacity in two other lean tools: PDCA and jidoka. PDCA stands for Plan-Do-Check-Act, a cycle of continuous improvement that helps you solve problems and implement changes. Jidoka means automation with a human touch, a concept that enables machines and workers to detect and stop defects and errors.

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Dhaval Patel

Lean coach at Metso | Lean Six Sigma Green Belt | Committed to Driving Operational Excellence and Continuous Improvement

1 Benefits of heijunka

Heijunka offers several advantages to your production system, such as cutting down on inventory and work-in-progress, which can save up space, capital, and resources. Quality and customer satisfaction are also improved with Heijunka, as it helps to deliver products that meet customer expectations and avoid defects and rework. Furthermore, it increases flexibility and responsiveness by allowing you to adjust production to match demand fluctuations and customer preferences. Additionally, employee morale and engagement are enhanced with Heijunka, as it creates a stable and predictable work environment that reduces stress and boredom.

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Dhaval Patel

Lean coach at Metso | Lean Six Sigma Green Belt | Committed to Driving Operational Excellence and Continuous Improvement
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In the PDCA and Jidoka systems, Heijunka, or production leveling, is used to balance demand and capacity by: Analyzing Demand: Understanding customer demand patterns to forecast and level production requirements. Capacity Assessment: Evaluating the organization's production capacity and capabilities. Smoothing Production: Using Heijunka to distribute production evenly over a specified period, preventing uneven demand spikes. Reducing Waste: Minimizing overproduction and inventory buildup, thus enhancing efficiency. Supporting Jidoka: Complementing Jidoka by creating a stable production environment, allowing for timely detection and resolution of issues.

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2 How to implement heijunka

To implement heijunka, you must begin by analyzing your production process and identifying the sources of variation, waste, and imbalance. Then, calculate your takt time, which is the rate at which you need to produce to meet customer demand. After that, divide your production into smaller and standardized batches or units that match the takt time and customer order sequence. Utilize a heijunka board, a visual tool that shows the planned production schedule and the actual progress of each batch or unit. Finally, monitor and adjust your production leveling according to the feedback from the heijunka board and customer demand.

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Mattia Costa

AI Prompt Engineering for Supply Chain Management | Driving E2E Supply Chain Value | Lean Six Sigma
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When I use Heijunka, I start by analyzing customer demand to identify patterns and smooth out production, avoiding peaks and valleys. In the PDCA cycle, I level the workload in the planning phase and adjust in the Check and Act phases to stay aligned with demand. For Jidoka, I keep production steady to catch and fix quality issues early without disruptions. I use tools like Heijunka boxes or boards to visualize and manage leveling, ensuring a consistent pace that matches capacity while staying flexible. This approach helps me reduce waste, improve efficiency, and maintain quality.

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3 How to use heijunka in PDCA

Heijunka can help you apply the PDCA cycle to your production process. Start by setting goals and objectives for production leveling, and identify the measures and indicators that will help evaluate performance. Then, implement heijunka in the production process and observe the results. Compare actual performance to planned performance, and analyze any gaps or deviations. Collect data and evidence to identify root causes of problems or issues, and take corrective and preventive actions to address them. Standardize best practices and solutions, revise goals and objectives, and plan for the next cycle of improvement.

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4 How to use heijunka in jidoka

Heijunka is a helpful tool for applying jidoka to production processes. Automate the process by using machines and equipment that can perform tasks efficiently and accurately, while detecting and signaling any defects or errors. If a defect or error occurs, stop the production process immediately and isolate the affected batch or unit. Then, find out the root cause of the defect or error by using tools such as the 5 whys, fishbone diagrams, or Pareto charts. Finally, implement countermeasures and controls to prevent recurrence of the defect or error and ensure quality and reliability of production. Be sure to document and share findings and actions with your team and stakeholders.

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5 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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How do you use heijunka or production leveling to balance demand and capacity in PDCA and jidoka systems?

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1 Benefits of heijunka

2 How to implement heijunka

3 How to use heijunka in PDCA

4 How to use heijunka in jidoka

5 Here’s what else to consider

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