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Heijunka box loading

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  • January 3, 2006 at 7:47 pm #41882

    Peter Chittick
    ★ 10 Years ★
    Participant

    Help! I am trying to figure out how to load a heijunka box to optimize the level loading of our production line.
    We have several parts going through the same line, I am trying to understand an easy way to load the heijunka box everyday, taking into account what parts need to be produced, at what quantity, & within what sequence to facilitate a mininum number of change-overs.
    I know there is software out there to assist with this, but I don’t want another software platform I have to deal with.
    Any one have a suggestion?

    0
    January 3, 2006 at 9:14 pm #131849

    ramblinwreck13
    ★ 20 Years ★
    Participant

    Look towards your Bottleneck operations for how you should load your Heijunka box. Capacity Constraints will gide you towards level loading of the rest of the line. Without knowing more about you operations or production methods, TAKT rates ect it is impossible to be more specific, but whenever I have had to level load in am mixed model environment it is always the bottle necks that determine the optimal scheduling sequences and parameters.
    Hope this helps

    0
    June 13, 2008 at 4:30 am #172810

    Anshuman Sharma
    ★ 10 Years ★
    Participant

    Heijunka is the Foundation of Lean , it means the alignment of your workforce with your workflow for the optimum utilization of available resources.
    I have made a heijunka (Level Loading) box for my process . See if it can help you

     
     
     
     
    Heijunka Box
     
     
     
     

    TIP (Things in Process)
    1
    10
    15
    23
    10
    5
    4
    3
    1
    20

    Timing Slots
    9am To 10am
    10am to 11am
    11am to 12pm
    12pm to 1pm
    1pm to 2pm
    2pm to 3pm
    3pm to 4pm
    4pm to 5pm
    5pm to 6pm
    6pm to 7pm

    Resource Available 
    1
    1
    1
    1
    1
    1
    1
    1
    1
    1

    Transaction Time in Mins
    5
    5
    5
    5
    5
    5
    5
    5
    5
    5

    Process capability
    12
    12
    12
    12
    12
    12
    12
    12
    12
    12

    Over and Under capacity/Transaction
    11
    13
    10
    -1
    1
    8
    16
    25
    36
    28

     
     
     
     
     
     
     
     
     
     
     

     
     
     
     
     
     
     
     
     
     
     

    Man Power Reduction
    0.7
     
     
     
     
     
     
     
     
     

     
     
     
     
     
     
     
     
     
     
     

    Note :- If outcome of Over and Under Capacity is Positive then it is means the Process is Over Capacitiazed and it is negative it means it’s Under capacitized
     
      
    Thanks
    Anshuman Sharma
     

    0
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