Toyota Case Study

707 Words3 Pages
Heijunka is a tool, or element of just-in-time (JIT) manufacturing, which allows for the smoothing of manufacturing activity over a given time frame, otherwise known as production leveling or level loading. In addition to some ancillary benefits discussed later in the paper, the primary goal of Heijunka is to balance production throughput to align with demand, through the coordinated sequencing of very small production batches. A hypothetical, legacy manufacturing example can be utilized to illustrate the concept. Our hypothetical manufacturer, Toyyoyo Industries, produces three models of microwave ovens, each available in two different exterior finishes, white or black. As a result of Toyyoyo’s last year-end review, they see demand for their model/color combinations resulted in the following distribution of total microwaves sold: White Model A | Black Model A | White Model C | Black Model B | Black Model C | White Model B | 300 | 280 | 150 | 150 | 80 | 40 | Demand for either color of Model A was the overwhelming choice of many consumers; however, new technology in power savings, output performance and additional stainless steel exterior options have Toyyoyo’s market research department convinced that demand for various models/colors has a high potential to fluctuate dramatically in coming years. Assuming Toyyoyo followed their traditional manufacturing scheduling process for the upcoming year’s production, they would intuitively begin with an initial setup and production run of 300 White Model As for two months, followed by a setup changeover of two days to commence manufacture of 280 Black Model A’s for subsequent two months. An additional setup changeover would result in an additional two days productivity loss to commence next batch run, and continue the cycle to eventually complete all 1000 units by year’s end. The end result of their
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