Production Leveling (Heijunka) Implementation in a Batch Production System: A Case Study

نویسندگان

  • Luciano Fonseca de Araujo
  • Abelardo Alves de Queiroz
چکیده

This paper presents a case study of an implementation of a new method for Production Leveling designed for batch production. It includes prioritizing criteria of products and level production plan. Moreover, it was applied on a subsidiary of a multinational enterprise located on Brazil, which manufacturing processes comprise batch production in a make-to-stock policy. Regarding a qualitative assessment, evidences show that the company had deficient practices related to Operations Planning. Thus, based on a case study approach, proposed method was applied as well empirical data were analyzed. Results were measured before and after this implementation by performance indicators of Costs (inventory), Speed (lead time), Mix flexibility (monthly set up operations) and Reliability (service level). Evidences confirm improvements in operational efficiency as expected. Researchers and practitioners can evaluate general applicability of this method by applying it in different companies that share similarities related to batch processing operations.

برای دانلود متن کامل این مقاله و بیش از 32 میلیون مقاله دیگر ابتدا ثبت نام کنید

ثبت نام

اگر عضو سایت هستید لطفا وارد حساب کاربری خود شوید

منابع مشابه

A Conceptual Model for Production Leveling (Heijunka) Implementation in Batch Production Systems

This paper explains an implementation model for a new method for Production Leveling designed for batch production system. The main structure of this model is grounded on three constructs: traditional framework for Operations Planning, Lean Manufacturing concepts for Production Leveling and case study guidelines. By combining the first and second construct, a framework for Production Leveling h...

متن کامل

Multivariate Simulation Analysis of Production Leveling (heijunka) - a Case Study

Production leveling (heijunka) is one of the lean tool that is used to stabilize a manufacturing system (reduce the bullwhip effect). Production leveling is a kind of cyclic scheduling that creates production regularity and coordination simplicity. This article describes simulation modeling and multivariate analysis of an assembly production line in a microelectronics factory. The assembly line...

متن کامل

Sizing of Heijunka-controlled Production Systems with Unreliable Production Processes

Heijunka is the notion to level a production system by removing ups and downs in volume caused by batch processing and customer order fluctuation in order to reach a mixed model production system with a constant flow of parts. We show how to implement lean production principles in systems with unreliable production processes. Process unreliabilities occur because tool machines may have small ov...

متن کامل

Models of Heijunka-levelled Kanban-systems

Heijunka is a key-element of the Toyota production system. It is used to level the release of production kanbans in order to achieve an even production program over all possible types of products thus reducing or eliminating the bullwhip effect. In this paper the dependencies between the parameters of the levelling process and the requirements in finished goods stocks are derived, resulting in ...

متن کامل

Dynamic modelling of impact of lean policies on production levelling feasibility

A dynamic systems approach is proposed to investigate challenges of implementing production leve and associated costs. A model of a lean cell is developed using system dynamics. The model capt various lean tools influencing production levelling. Comparative cost analysis between various leve implementation policies for stochastic demand with multiple products is conducted. Results showed determ...

متن کامل

ذخیره در منابع من


  با ذخیره ی این منبع در منابع من، دسترسی به آن را برای استفاده های بعدی آسان تر کنید

برای دانلود متن کامل این مقاله و بیش از 32 میلیون مقاله دیگر ابتدا ثبت نام کنید

ثبت نام

اگر عضو سایت هستید لطفا وارد حساب کاربری خود شوید

عنوان ژورنال:

دوره   شماره 

صفحات  -

تاریخ انتشار 2009