A simulation-oriented approach to the design of Kanban integrated Heijunka system

Abstract

Heijunka is a Japanese term that refers to a lean manufacturing approach used to reduce variability in production processes. Heijunka also known as production levelling was developed and implemented as a part of the Toyota Production System. The main purpose of Heijunka is to create a lean production process that is least affected by demand fluctuations. This method aims to decrease overproduction by aligning production plan with actual customer demand, avoiding bulk production in batches, and promoting a more balanced production flow. This paper presents a simulation-oriented approach to the design of a Kanban-controlled Heijunka system for the manufacture of automotive seal solutions. With the developed simulation model, the potential outputs of the planning pattern were estimated according to the demand fluctuations. Obtained results show that potential decreases in WIP stock levels and faster deliveries to the customers can be achieved. (Received in October 2024, accepted in March 2025. This paper was with the authors 2 weeks for 1 revision.)