What results in increasing change over flexibility and efficiency that protects a production line from demand ambushes?
forecasts
What is mura?
the unevenness in productivity and quality
What is muri?
the overburden of machines, managers, and production associates
What do mura and muri cause?
waste
What did Toyota manager conclude was the best way to run manufacturing?
calculate long term demand for the product in question and to run the production process very smoothly at the level of long term demand
What is the size of inventory proportional to?
the degree of variability in customer demand
What is Toyota's calculation for leveling production?
calculate standard inventory of finished goods at the end of the production process for make-to-stock items
What can carrying extra inventory at the end of the process do?
smooth production all the way upstream and reduce inventories at every juncture between flow and pull along the system
What does leveling for overall demand do?
protects the process from giant demand waves and troughs
What is the 2nd aspect of heijunka?
leveling output by product mix
What has been traditionally used in manufacturing?
batching
What is batching?
product processed at the same time and under the same conditions, each item being identifiable as identical for classification purposes
How does heijunka fix issues with batching?
by releasing only enough orders of all parts to meet takt time demand
What size of batches are ideal in lean systems?
small
What kind of environment does lean thrive in?
high product variation
What is EPEX?
producing every product during every relevant time frame
What is reduced with EPEX?
lead time
What is the business closer to meeting when using EPEX?
real" demand
What is the catch of heijunka?
changeover time
What percent of changeover time is common in heijunka?
10%
How is heijunka implemented?
the heijunka box
What are the rows in a heijunka box?
what needs to be produced
(ex. 3 rows for widgets, gizmos, and thingamabobs)
What are the columns in the heijunka box?
divided by time or pitch
What is pitch?
the smallest takt time multiplied by quantity produced