Course Content:

Introduction to Load Leveling (Heijunka) in Lean Six Sigma:
Understanding the concept and importance of Heijunka.
How load leveling aligns with Lean Six Sigma principles and methodologies.

Benefits of Load Leveling:
Exploring the advantages of smoothing production or workflow, including reduced waste, improved customer satisfaction, and cost savings.

Load Leveling Principles:
Key principles and considerations in load leveling, including takt time, work sequence, and production stability.

Takt Time Calculation:
Understanding takt time as the heartbeat of production.
Calculating takt time to match customer demand.

Work Sequence and Batch Size Reduction:
Strategies for optimizing work sequences and reducing batch sizes.
Minimizing overproduction and inventory.

Kanban Systems for Load Leveling:
Implementing Kanban systems to signal production and maintain flow.
Pull-based production and Just-in-Time (JIT) principles.

Production Smoothing Techniques:
Techniques for smoothing production schedules and minimizing production fluctuations.
Implementing production smoothing boards.

Mixed-Model Production:
Introduction to mixed-model production and its role in load leveling.
Balancing production of multiple product variants.

Visual Management for Load Leveling:
Incorporating visual cues, Andon systems, and status boards to enhance load leveling operations.
Real-time monitoring and problem identification.

Capacity Planning and Flexibility:
Assessing and adjusting production capacity to match customer demand.
Strategies for maintaining flexibility in load leveling.

Changeover Reduction and Standardized Work:
Reducing changeover times to enable quicker response to demand changes.
Developing standardized work instructions for load leveling processes.

Quality Control in Load Leveling:
Implementing quality control measures and mistake-proofing devices.
Reducing defects and rework in load leveled processes.

Employee Training and Engagement:
Training employees on load leveling principles and techniques.
Involving employees in the load leveling process and decision-making.

Monitoring and Continuous Improvement:
Implementing performance metrics and monitoring systems for load leveling.
Encouraging a culture of continuous improvement in load leveling.

Customizing Load Leveling for Your Organization:
Tailoring load leveling principles and techniques to suit the specific needs and context of your organization or industry.
Addressing industry-specific requirements.