Stabilize Your Operations and Eliminate Costly Peaks & Valleys

Our Production Leveling & Demand Smoothing service implements proven Heijunka strategies to balance your production flow, reduce inventory waste, and align output with true customer demand.

Key Deliverables:

  • Demand Analysis & Takt Time Calculation

    • Customer demand pattern evaluation

    • Optimal production pace determination

  • Heijunka Box Implementation

    • Visual scheduling system design

    • Mixed-model production planning

  • Workflow Rebalancing

    • Equipment and labor capacity leveling

    • Batch size reduction strategies

  • Inventory Optimization

    • Buffer stock right-sizing

    • Pull system implementation

Documented Outcomes:

✔ 30-50% reduction in production fluctuations
✔ 20-35% decrease in finished goods inventory
✔ 15-25% improvement in on-time delivery
✔ 10-20% reduction in overtime costs

Who This Benefits Most:

Operations experiencing:

  • Erratic production schedules

  • Chronic overtime followed by downtime

  • Excessive finished goods inventory

  • Missed deliveries despite high inventory

Implementation Process:

  1. Current State Analysis (1-2 weeks)

  2. Pilot Cell Implementation (3-4 weeks)

  3. Full Production Leveling (2-3 months)

Take the Next Step:
[Request Heijunka Assessment]