Factory Automation | Heijunka in Action: How Position Automation Enables Production Leveling
In lean manufacturing, consistency is king. But customer demand is rarely consistent. That’s where Heijunka, the principle of production leveling: comes in for factory automation.
At Position Automation, we design systems that help manufacturers smooth out the peaks and valleys of production, reduce variation, and build a more stable, predictable flow.
What Is Heijunka?
Heijunka (pronounced hi-june-ka) is a Japanese term meaning “leveling.” It’s a lean strategy that spreads production evenly over time to:
- Avoid overburdening machines or workers (Muri)
- Prevent uneven workloads (Mura)
- Reduce inventory and lead time
- Improve responsiveness to customer demand
Rather than producing in large batches, Heijunka encourages small, frequent, and balanced production, even when demand fluctuates.
How Position Automation Supports Heijunka
Our factory automation solutions are designed to adapt quickly and run consistently, ideal for levelled production. Here’s how we help:
- Flexible Programming: Easily switch between product types without long setup times.
- Quick Changeovers (SMED): Modular tooling and saved recipes reduce downtime between runs.
- Consistent Cycle Times: CNC precision ensures predictable output across shifts.
- Lights-Out Capability: Run smaller batches overnight without operator intervention.
- Real-Time Monitoring: Track production flow and adjust schedules based on actual demand.
Real World Example: Leveling the Load
A client producing structural profiles faced erratic order volumes: some days overloaded, others underutilised. They struggled with:
- Long lead times
- Excess inventory
- Operator fatigue
With Position Automation’s system:
- Production was broken into smaller, levelled batches
- Machines ran overnight to meet peak demand
- Setup time was reduced, enabling more frequent changeovers
- Output became more predictable, and customer satisfaction improved
Heijunka + Automation = Flow Without Friction
When you level production, you unlock:
- Smoother workflows
- Balanced workloads
- Reduced stress on people and machines
- Faster, more reliable delivery
At Position Automation, we help you build systems that don’t just react to demand, they absorb it with grace.
Ready to Level Up?
Heijunka isn’t about slowing down, it’s about smoothing out. And with Position Automation, you can build a production system that’s flexible, balanced, and built for the long haul.
Follow us for more lean tools, factory automation strategies, and case studies that show lean in motion – one levelled schedule at a time.
