Heijunka Jundate Kanban

The article establishes the connection between Toyota Lean Manufacturing ideas of Heijunka, Kanban, Jundate and also associated concepts of Nenkei, FIFO and DDR for efficient utilization of plant capacity.

In order for a multi-product manufacturing plant with single line to run at a destined efficiency, it is necessary to ensure Heijunka in Nenkei i.e., even-ness in production plan.

To achieve said condition, the material supply to working stations shall have to be on Jundate type i.e., JIT basis. Since DDR cannot be 100%, FIFO is disturbed which has to be rectified in buffer area. The Kanban system then communicates instantaneous information for supply.

Since production capacities are calculated on homogenous distribution of product mix, any deviation from Heinjuka will directly have adverse effect on production capacity on exponential basis.?The only solution to achieve desired production capacity would be with increase in warehousing capacities with cumbersome stock management.

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