Heijunka in Lean Six Sigma: Smoothing the Flow for Efficiency In Lean Six Sigma, Heijunka —a Japanese term meaning "leveling"—is a powerful technique used to eliminate waste ( muda ) and create a more predictable, efficient production system. Often referred to as Production Leveling or Production Smoothing , Heijunka helps organizations manage variability in demand and workload by distributing production evenly over time. The Purpose of Heijunka The core idea behind Heijunka is to produce intermediate goods at a constant rate , enabling downstream processes to operate smoothly and predictably. This approach minimizes bottlenecks, reduces inventory, and improves overall flow. Rather than reacting to fluctuating customer demand with uneven production schedules, Heijunka encourages a steady rhythm that aligns with long-term demand averages. This helps avoid overproduction, underutilization, and excessive lead times. Key Techniques Associated with Heijunka Three essential Lean...
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