Level production with Heijunka and Sequencer
Two Tools to Tackle Fluctuating Demand
KanbanBOX is the right software for managing electronic kanban systems. With built-in Heijunka and Sequencer features, it helps you effectively address the challenges of unstable demand, improve productivity, and avoid the risks associated with overproduction.
With KanbanBOX’s Heijunka and Sequencer tools, you can:
-
Smooth out production fluctuations, eliminating the continuous cycle of peaks and downtimes caused by demand variability
-
Reduce shortages and inefficiencies resulting from irregular production activities, such as machine stoppages, supply delays, and wasted resources (raw materials, time, unsold finished goods)
-
Align production with actual customer needs, ensuring a steady workflow while avoiding overproduction and stockouts
The Benefits of Using KanbanBOX for Production Leveling
Regularity
Effectively mitigate the issues caused by inconsistent demand, which often leads to a disruptive cycle of high-stress periods followed by slowdowns in production.
Efficiency
By reducing production spikes and idle times, you also avoid related inefficiencies, like equipment downtime, early or late deliveries, supply chain disruptions, and wasted resources.
Visibility
Whether you manage one plant or multiple facilities, having full visibility into the production process is essential. KanbanBOX’s visual board gives you clear, complete control over every operation.
What Are Heijunka and Sequencer and How Do They Work?
Heijunka: Stabilize the Production Rhythm
Heijunka is a Lean tool for production leveling that distributes workloads evenly across production cells, stabilizing both the pace of production and resource usage. It helps standardize component consumption and minimize supply fluctuations.
Key benefits of a Heijunka system:
- Leveling of production volume
- Leveling of product mix
- Elimination of consumption peaks
- Avoidance of inventory buildup
- Even distribution of labor, materials, and movements
Heijunka in KanbanBOX makes it easy to apply these principles in real production environments.
Sequencer: Distribute the Workload
The Sequencer is a production leveling tool that distributes the workload across production machines by determining the optimal production sequence.
This gives the production supervisor clear visibility into the full workload and enables effective distribution of tasks among available machines.
The Sequencer is the ideal solution in scenarios where production isn’t consistent and:
-
There is process variability
-
Resources are not always available
In such cases, a strict Heijunka approach may not be feasible, making the Sequencer the perfect alternative.
Learn how to level up your production with Heijunka
Heijunka is a Lean method for leveling production by distributing workloads evenly across production cells while minimizing supply fluctuations.
Read moreDefine the processing sequence with the Sequencer
The Sequencer is a Lean Manufacturing tool for scheduling the best sequence of operations on production machines or work unites, optimizing resources effectively
Discover moreSimplify Your Production Planning
With KanbanBOX, it’s easy to optimize production planning. The system allows operators at every station to keep working without interruptions, even in dynamic and variable production environments.
Watch the videoReferences
Case studies
Robopac | Packaging machines
With KanbanBOX, Robopac achieved a more integrated, responsive, and digitalized supply chain thanks to the integration with both external suppliers and SAP
BCS | Agricultural Mechanization
BCS moved from push to pull through E-kanban for suppliers, production, and internal flows. They now manage 6000 kanban loops across 3 plants and integrated KanbanBOX with SAP
El.Co. | Industrial Electrical Automation
El.Co. has simplified the maintenance of kanbans with e-kanban, which was previously so onerous that the number of parts managed by kanban had to be limited
Orotig | Welding Industry
Orotig has implemented sequential pull in the company, optimizing multi-process production scheduling and supplier integration with KanbanBOX
Rossi SpA | Gearmotors and Electric Motors
Rossi Spa has digitalized the existing production and move kanban, and then integrated it with its own ERP, with the Oracle Sequencer and with the suppliers
Aptiv | High-tech automotive systems
From the introduction of kanban to the transition to e-kanban. The Lean Improvement journey of the largest manufacturer of electronic interconnection systems for the automotive sector