What is Heijunka and how is it connected to changeover time?
Why shorter changeover times are important for reducing WIP?
1 Article for the week:
What is the connection between SMED and Load Levelling (Heijunka)? People think they are 2 isolated tools in Lean manufacturing. However, they are extremely dependent on each other.
SMED (Quick changeover) focuses on reducing the change-over time in the machines. It improves the machine availability thereby improves the overall productivity.
Load Levelling (Heijunka) is about manufacturing multiple products (Product mix) at fixed quantities (small batches) to meet the customer’s demands. Heijunka adds flexibility and reduces inventories (WIP).
Are they dependent on each other? Yes. Only if the changeover time is small, we would be able to implement Heijunka.
If the changeover times is high, people would not prefer to do multiple changeovers. Infrequent changeovers leading to large lot size- Product which takes more setting time will be avoided by the personnel.
So they continue to run the same product for a longer time resulting in high inventory, whereas other products may be in demand.
Heijunka is possible only if the changeover time is less. So SMED and Heijunka are dependent on each other.
Infact a lot of lean tools are dependent on each other. Generally people think that these tools can be implemented in isolation. But they are not. We’ll discuss in detail about this content in our next article.
If you are interested in training your team on Shop Floor Management, our course can help. Check it out here.
2 Quotes for the week:
“The only difference between ordinary and extraordinary is that little extra.” ―Jimmy Johnson
“The best way to appreciate your job is to imagine yourself without one.” ―Oscar Wilde
3 Image for the week:
