Transforming Your Value Streams Workbook

Transcription

1 Transforming Your Value Streams Workbook Before kanban can work we must level production. In this module you will earn what heijunka is. A workbook intended to accompany the Facilitator s Guides for this course. This guide includes the Key Points from the video, discussion items, quiz questions, and helpful tips. Using Gemba Academy s online learning content, any participant can use this workbook to facilitate learning in all courses. July 2017

2 Review What is Heijunka? Heijunka refers to a system of production by both volume and mix. Before we study heijunka in more depth, we must introduce two concepts: Mura ( ): one of the most challenging things in any business is varying customer demand, especially when you think you know what they want. Muri ( ): as a result of varying customer demand, companies often overburden their employees and equipment. A related concept is the effect. At the beginning of the month or quarter, there isn t much work to do, but near the end of the month, employees often work mandatory overtime to meet demand. Your suppliers might feel more pain than your company does when experiencing uneven demand by the effect. A small variation in demand can create a massive variation in supply, much like the flick of a wrist can produce massive force at the end of a bullwhip. Before leveling, resources are required for peak demand seasons and not required for slow seasons. This frustrates employees and makes for an uneven process. After leveling, we are better able to schedule resources in a more and respectful fashion. What Does Heijunka Look Like? Lot Production: Uneven production, leads to excess inventory or lost customer orders. Weekly Leveling: Not quite as even as pure heijunka, this requires even more changeovers than the lot production system, making quick changeovers a necessity. Daily Heijunka Production Scheduling: The volume is leveled per day and the mix is leveled within each day. The number of changeovers exponentially increases, so quick changeovers (supported by good 5S, reliable machines, and stable processes) are absolutely critical. 1

3 Additional Benefits of Heijunka Leveling allows us to make what the customer wants when they want it. This helps us dramatically reduce the amount of slow moving or obsolete. flow and standard work can be established, since production follows a pattern and the level mix provides a stable workload. This helps reduce cost and improve quality. We are able to our signals throughout the supply chain. Leveling also allows our suppliers to limit their inventory, deliver set quantities on a routine basis, and avoid the bullwhip effect. Prerequisites to Heijunka Since the number of changeovers required is exponentially greater, Single Minute Exchange of Dies (SMED) and Total Productive Maintenance (TPM) are crucial. Once these systems are in place, we can produce according to what we sell. The Heijunka box: this is a common tool for implementing leveling. It allows us to schedule exactly when a product should be produced by matching product families (and their kanban cards) with time periods. 2

4 Quiz 1. Heijunka refers to a system of production by both volume and mix smoothing or leveling flow acceleration pull 2. Means unevenness. Muda Mura Muri 3. Means to overburden. Mura Muri Muda 4. The ability to setup (changeover) equipment is crucial for heijunka to work properly. True False 5. What are some advantages of implementing heijunka? Please select all that apply. We re able to intensify both the hockey stick and bullwhip effect. You make what the customer wants when they want it (JIT) It becomes possible for smooth one-piece flow and standard work to be established. We re able to smooth signals throughout the supply chain. 6. The number of setups (changeovers) required will likely increase when heijunka is implemented. True False 3

5 Reflection Do you see any opportunities to implement heijunka in your workspace? Do you think you have the prerequisite conditions for heijunka? 4