TECHNOLOGIES

Planning the inflow of products for production levelling

  • 1 Faculty of Mechanical Engineering and Management – Poznan University of Technology, Poland

Abstract

Production levelling, also referred to as production smoothing (jap. Heijunka), is an effective method for reducing unevenness in the production process and maintaining better control over stock levels. It helps keep production at a steady pace and ensure the desired level of flexibility. The authors present a study aimed at developing a method for planning the inflow of products from the production process, intended to be used in the scheduling of levelled production. Focus has been put on finding the right combination of lot size and production interval which, assuming certain input parameters (order size and placement rate, initial stock levels), yields the best outcome in terms of timely/untimely order fulfilment and minimum and maximum stock levels.

Keywords

References

  1. Liker J.K., The Toyota way, 14 management principles from the worlds greatest manufacturer, 1st edn., New York: McGrawHill, 2004
  2. Korytkowski P., Grimaud F., Dolgiu A., Exponential smoothing for multi-product lot-sizing with heijunka and varying demand, Management and Production Engineering Review, Vol. 5, No 2, p. 20-26, 2014
  3. Dolgui A., Proth J.M., Supply chain engineering: useful methods and techniques, London: Springer, 2010
  4. Rother M., Toyota Kata: Managing People for Continuous Improvement and Superior Results, New York: McGraw-Hill, 2009
  5. Liker, J.K., The Toyota Way, McGraw-Hill, New York, 2004
  6. Araujo L.F.D., Queiroz A.A.D., A Conceptual Model for Production Leveling (Heijunka) Implementation in Batch Production Systems, Advances in Production Management Systems. New Challenges, vol. 338. Springer, 2010
  7. Lippolt, C. R., & Furmans, K., Sizing of heijunka-controlled production systems with unreliable production processes, Lean business systems and beyond, vol. 257, pp. 11–19, Springer, 2008
  8. Kerber B. Dreckshage B.J., Lean Supply Chain Management Essentials. A Framework for Materials Managers, CRC Press, Boca Raton, 2011
  9. Rewers P., Hamrol A., Żywicki K., Kulus W., Bożek M., Production Leveling as an Effective Method for Production Flow Control - Experience of Polish Enterprises, Procedia Engineering, vol. 182, pp. 619-626, 2017
  10. Rewers P., Trojanowska J., Diakun J., Rocha A., Reis LP, A Study of Priority Rules for a Levelled Production Plan, Advances in Manufacturing. Lecture Notes in Mechanical Engineering, pp. 111-120Springer, 2018
  11. Żywicki K., Rewers P., Bożek M., Data Analysis in Production Levelling Methodology, Advances in Intelligent Systems and Computing, vol. 571, pp. 460-468, Springer, 2017
  12. Rewers P., Żywicki K., Diakun J., Comparison Study of Different Production Control Policies in Condition of Various Demand for Final Products, Advances in Manufacturing II Volume 2 - Production Engineering and Management, Lecture Notes in Mechanical Engineering, pp. 268-280, Springer, 2019
  13. Hüttmeir A., Treville S., Ackere A., Monnier L., Prenninger J., Trading off between heijunka and just-in-sequence. Int. Journal Production Economics, vol. 118, pp. 501-507, 2009
  14. Coleman, J.B., Vaghefi, M., Heijunka: a key to the Toyota production system. Production & Inventory Management Journal, vol. 34 no. 4, pp. 31-35, 1994
  15. Xiaobo, Z., Zhou, Z. and Asres, A., A note on Toyota’s goal of sequencing mixed models on an assembly line. Computers & Industrial Engineering, vol. 36, pp. 57-65, 1996
  16. Teece, D.J., Pisano, G., Shuen, A., Dynamic capabilities and strategic management. Strategic Management Journal, vol. 18 (7), pp. 509–533, 1997
  17. Andel, T., Accentuate heijunka, eliminate junk, supply chain flow. Material Handling Engineering, vol. 54 no. 8, pp. 77, 1999
  18. Araujo, L.F.D., Queiroz, A.A.D., Production Leveling (Heijunka) Implementation in a Batch Production System: A Case Study, International Federation For Information Processing, pp. 105–112, 2010
  19. Monden, Y., Toyota Production System. Industrial Engineering and Management Press, Institute of Industrial Engineers, Norcross, GA, 1983
  20. Van Staden M., Du Plessis W., Being the lean dream. CIE42 Proceedings, 16-18 July 2012, Cape Town, South Africa, 2012
  21. Abdulmalek F.A., Rajgopal J., Analyzing the benefits of lean manufacturing and value stream mapping via simulation: A process sector case study, International Journal of Production Economics, vol. 107 no. 1, pp. 223–236, 2007
  22. Runkler T.A., Controlling discrete manufacturing processes using Kanban and Heijunka approaches, 9th IEEE International Conference on Industrial Informatics, pp. 181–186, 2011
  23. Bohnen F., Maschek T., Deuse J., Leveling of low volume and high mix production based on a Group Technology approach, Journal of Manufacturing Science and Technology, vol. 4, pp. 247-251, 2011
  24. Buhl, M., Bohnen, F., Deuse, J., Schneider, R., Effiziente Kleinserienfertigung durch Produktionsnivellierung, Productivity Management, vol. 14, pp. 19–22, 2009

Article full text

Download PDF