Abstract
Traditional companies usually manufacture
high-quantity batches in order to meet the customer demand and increase
production efficiency. Manufacturing with high-quantity batches may lead to
fewer die change operations, but this causes on the other hand the inflation of
stocks, the probability of defects in high quantities, increasing the variance
and excessive idle time or overtime. In the age of Industry 4.0 where the
competition is so fierce, this kind of a production approach does not only
cause financial loss but also leads to a significant amount of market share. Therefore, companies today deploy new approaches with
the support of management information technologies in order to achieve
operational flexibility and perform custom-made production for customers. One
of these approaches is Heijunka, which is among the lean management techniques
and initially used at Toyota. Being one of the cornerstones of Toyota
manufacturing system, Heijunka is utilized to meet varying customer demands in
the same period of time and decrease the variance. In order to decrease the
variance, Heijunka eliminates not only the waste (muda) but also the overload
on machines and workforce (muri) and the irregularity (mura). This ensures that
the product demanded by the customer is manufactured at the requested point of
time, by assuring a more equal reflection of demand variations and/or
deficiencies of planning to the production process.
The
aim of this study is to familiarize both the industry and the academy with
Heijunka by examining the technique with all of its traits and contribute to
the dissemination of its use.
Keywords
Lean Management Optimization of Production Management Management Information System Heijunka Industry 4.0 and New Approach at Industry Management Production Management
References
- Boysen, N., Fliedner, M. and Scholl, A. (2007). Sequencing mixed-model assembly lines: survey, classification and model critique. European journal of operational research, [In Press, Corrected Proof]. (Hakansson)
- Çetin Gerger, G. (2019). Tax Services and Tax Service Providers’ Changing Role in the IoT and AmI Environment. In: Mahmood Z. (eds) Guide to Ambient Intelligence in the IoT Environment. Computer Communications and Networks. Cham: Springer.
- Coleman, B. Jay and Vaghefi, M. Reza (1994). Heijunka (?): A key to the Toyota production system. Production and Inventory Management Journal; Fourth Quarter 1994; 35, 4; ProQuest Central, pg. 31-35.
- Dave, Y. and Sohani, N. (2012). Single Minute Exchange of Dies: Literature Review. International Journal of Lean Thinking, Volume 3, Issues 2 (December 2012).
- Gerger, A. (2017). Use Of Six Sigma Method As A Process Improvement Technique (Unpublished undergraduate dissertation). Dokuz Eylül University, Izmir.
- Gerger, A. and Firuzan, A. R. (2012). Reasons of Failure in Lean Six Sigma Projects. International Journal of Multidisciplinary Thought, 2 (3), 123–130.
- Hakansson, J., Skoog, E. and Eriksson, K. A review of assembly line balancing and sequencing including line layouts. University west Department of Engineering Science 461 86 Trollhattan.
- İşler, M. and Güner, M. (2014). Heijunka Technique from Lean Production Tools and Its Apparel Applications. 8th International Izmir Textile and Apparel Symposium, April 2-5, 353-356.
- Jones, D. T. (2006). Heijunka: Leveling production. Manufacturing engineering, 37(2), 29-36.
- Liker, J. K. (2004). The Toyota way: 14 management principles from the world's greatest manufacturer. NY: McGraw-Hill.
- Lippolt, C.R. and Furmans, K. (2008). Sizing of Heijunka-controlled Production Systems with Unreliable Production Processes. IFIP International Federation for Information Processing, Volume 257, Lean Business Systems and Beyond, Tomasz Koch, ed.; (Boston: Springer), pp. 11–19.
- Matzka, J., Mascolo, M.D. and Furmans, K. (2012). Buffer sizing of a Heijunka Kanban system. J Intell Manuf (2012) 23:49–60, DOI 10.1007/s10845-009-0317-3
- Ramekar, A. M., Muneshwar, V.D., Kute, A.S. and Choube, A.M. (2017). Concept of Heijunka. International Advanced Research Journal in Science, Engineering and Technology, Vol. 4, Special Issue 3, January 2017, DOI 10.17148/IARJSET.
- Rizvi, H. R. (2013). Application of Lean-Six Sigma Approach in a Laboratory Experimental Case Study. International Journal of Lean Thinking, Volume 4, Issue 2 (December2013).
- Sharma, M. (2017). What is Heijunka and what are Muda Muri & Mura?. Çevrimiçi https://www.youtube.com/watch?v=sRbG_zjsrPs&t=141s
- Shingo, S. (1985). A Revolution in Manufacturing: The SMED System. Portland: Productivity Press Inc.
- Swanson, R. E. (2008). A Generalized Approach to Demand Buffering and Production Levelling for JIT Make- to-Stock Applications. The Canadian Journal of Chemical Engineering, Volume 86, October 2008, DOI 10.1002/cjce.20093.
- Taleghani, M. (2010). Key factors for implementing the lean manufacturing system. Journal of American Science, 6 (7), 287-291.
- Womack, J. P. and Jones, D. T. (1996). Lean Thinking: Banish Waste and Create Wealth in Your Corporation. NY: Simon & Schuster.
Abstract
Geleneksel
firmalar müşteri talebini karşılamak ve üretim verimini arttırmak için
genellikle yüksek adetli partiler halinde üretim yapmaktadırlar. Aynı üründen
büyük miktarlarda üretmek belki daha az kalıp değişimine neden olmaktadır.
Ancak; bu durum genellikle stokların şişmesine, büyük miktarlı hata
olasılıklarının oluşmasına, değişkenliğin artmasına ve aşırı boş zamana ya da
fazla mesaiye neden olabilmektedir. Rekabetin bu denli yoğun yaşandığı Endüstri
4.0 çağında firmanın bu üretim tarzı sadece para kaybetmek anlamına gelmeyip
aynı zamanda ciddi pazar kaybı yaşamasına neden olmaktadır.
Bunun için
firmalar, operasyonlarında esnekliği sağlamak ve müşteriye özgü üretim
gerçekleştirebilmek için yönetim bilişim sistemlerinin de desteğiyle yeni
yaklaşımlar kullanmaktadırlar. Bu yaklaşımlardan biri de Yalın Yönetim
tekniklerinden biri olan ve ilk olarak Toyota’da kullanılmaya başlayan
Heijunka’dır. Toyota üretim sisteminin köşe taşlarından biri olan Heijunka,
aynı zamanda farklı müşteri taleplerini karşılamak ve değişkenliği azaltmak
için kullanılır. Heijunka, değişkenliği azaltmak için sadece israfları (muda)
değil aynı zamanda makine ve insanlar üzerindeki aşırı yükü (muri) ve
düzensizliği de (mura) ortadan kaldırır. Böylece müşteri taleplerinden ve/veya
planlama eksikliklerinden meydana gelebilecek talep dalgalanmalarının üretime
daha dengeli bir şekilde yansımasını sağlayarak, müşterinin istemiş olduğu
ürünün istemiş olduğu zamanda üretilmesini sağlar.
Bu
çalışmayla; Heijunka tekniğinin tüm yönleriyle ele alınarak endüstride ve
akademide tanınması ve kullanımının yaygınlaştırılması hedeflenmiştir.
Keywords
Yalın Yönetim Üretim Yönetim Optimizasyonu Yönetim Bilişim Sistemleri Heijunka Endüstri 4.0 ve Endüstride Yeni Yaklaşımlar Üretim Yönetimi
References
- Boysen, N., Fliedner, M. and Scholl, A. (2007). Sequencing mixed-model assembly lines: survey, classification and model critique. European journal of operational research, [In Press, Corrected Proof]. (Hakansson)
- Çetin Gerger, G. (2019). Tax Services and Tax Service Providers’ Changing Role in the IoT and AmI Environment. In: Mahmood Z. (eds) Guide to Ambient Intelligence in the IoT Environment. Computer Communications and Networks. Cham: Springer.
- Coleman, B. Jay and Vaghefi, M. Reza (1994). Heijunka (?): A key to the Toyota production system. Production and Inventory Management Journal; Fourth Quarter 1994; 35, 4; ProQuest Central, pg. 31-35.
- Dave, Y. and Sohani, N. (2012). Single Minute Exchange of Dies: Literature Review. International Journal of Lean Thinking, Volume 3, Issues 2 (December 2012).
- Gerger, A. (2017). Use Of Six Sigma Method As A Process Improvement Technique (Unpublished undergraduate dissertation). Dokuz Eylül University, Izmir.
- Gerger, A. and Firuzan, A. R. (2012). Reasons of Failure in Lean Six Sigma Projects. International Journal of Multidisciplinary Thought, 2 (3), 123–130.
- Hakansson, J., Skoog, E. and Eriksson, K. A review of assembly line balancing and sequencing including line layouts. University west Department of Engineering Science 461 86 Trollhattan.
- İşler, M. and Güner, M. (2014). Heijunka Technique from Lean Production Tools and Its Apparel Applications. 8th International Izmir Textile and Apparel Symposium, April 2-5, 353-356.
- Jones, D. T. (2006). Heijunka: Leveling production. Manufacturing engineering, 37(2), 29-36.
- Liker, J. K. (2004). The Toyota way: 14 management principles from the world's greatest manufacturer. NY: McGraw-Hill.
- Lippolt, C.R. and Furmans, K. (2008). Sizing of Heijunka-controlled Production Systems with Unreliable Production Processes. IFIP International Federation for Information Processing, Volume 257, Lean Business Systems and Beyond, Tomasz Koch, ed.; (Boston: Springer), pp. 11–19.
- Matzka, J., Mascolo, M.D. and Furmans, K. (2012). Buffer sizing of a Heijunka Kanban system. J Intell Manuf (2012) 23:49–60, DOI 10.1007/s10845-009-0317-3
- Ramekar, A. M., Muneshwar, V.D., Kute, A.S. and Choube, A.M. (2017). Concept of Heijunka. International Advanced Research Journal in Science, Engineering and Technology, Vol. 4, Special Issue 3, January 2017, DOI 10.17148/IARJSET.
- Rizvi, H. R. (2013). Application of Lean-Six Sigma Approach in a Laboratory Experimental Case Study. International Journal of Lean Thinking, Volume 4, Issue 2 (December2013).
- Sharma, M. (2017). What is Heijunka and what are Muda Muri & Mura?. Çevrimiçi https://www.youtube.com/watch?v=sRbG_zjsrPs&t=141s
- Shingo, S. (1985). A Revolution in Manufacturing: The SMED System. Portland: Productivity Press Inc.
- Swanson, R. E. (2008). A Generalized Approach to Demand Buffering and Production Levelling for JIT Make- to-Stock Applications. The Canadian Journal of Chemical Engineering, Volume 86, October 2008, DOI 10.1002/cjce.20093.
- Taleghani, M. (2010). Key factors for implementing the lean manufacturing system. Journal of American Science, 6 (7), 287-291.
- Womack, J. P. and Jones, D. T. (1996). Lean Thinking: Banish Waste and Create Wealth in Your Corporation. NY: Simon & Schuster.
Details
| Primary Language | Turkish |
|---|---|
| Journal Section | Articles |
| Authors | |
| Publication Date | July 3, 2019 |
| Published in Issue | Year 2019 Volume: 2 Issue: 1 |
