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Advanced Pull Manufacturing with Heijunka

  • Overview
  • Course Outline
  • For Whom
  • Other Details
  • Related Trainings
An ideal Lean manufacturing facility operates to the beat of customer demand and holds just enough inventory to keep production going. Material is “pulled” in to replenish actual usage rather than purchased based on a minimum order quantity (MOQ).

Production processes are linked and operate according to “takt time”. Scheduling is based on actual demand instead of on forecast.

This programme aims to help participants understand :
  • The workings of an end-to-end pull system
  • The concept of load-levelling
  • Use of a signaling system to replenish material consumed at production stations and keep material flowing through the production processes
  • The use of batch box and load-levelling box ie.heijunka.
Upon completion of this programme, participants are able to understand:
  • How an end-to-end pull system operates
  • The use of load-levelling and a load-levelling board to effectively replace traditional production scheduling for a constant demand high-mix condition
  • How a batch box can be used to signal production
  • The use of FIFO lanes for production processes
This programme combines theory with a simulation activity to convey the concept of an end-to-end pull system in a constant demand high-mix manufacturing operation. Various Lean tools are introduced and delegates get a hands-on approach to how these tools can benefit the manufacturer.

Day 1
  •    Key concepts of Lean
    •   7 Wastes
    •   5 Principles
  •    Types of Manufacturing Strategies
    •    Make to Stock/Forecast
    •    Make/Build to Order
    •    Configure to Order
    •    Build to Ship/Truck
  •    Just-In-Time
  •    Characteristic of a Pull System
    •    Push versus Pull
    •    Replenishment Pull
    •    Sequential Pull
    •    Mixed Pull
  •    Design ‘Future’ State VSM
  •    Lean tools and techniques
    •    FIFO lanes
    •    Supermarket and Buffer Stock
    •    Water Spider (Mizusumashi)
    •    Kanban Pull System
    •    2-Bin Pull system
    •    Batch Box Pull system
    •    Load-Levelling with Heijunka
  •    Level Loading Exercise
  •    Overview of the Pull System simulation   
Day 2
  •    Simulation briefing
  •    Simulation activity : Round 1
  •    Team assignment and presentation
  •    Simulation activity : Round 2
  •    Summary of key learning points
  •    Course review and summary
This programme is suitable for Managers, Executives and Supervisors from manufacturing facilities, which have to meet high mix customer demand.
This is a two-day course running from 9.00 am to 5.00 pm.

Code Title Location
LEA01 Lean Manufacturing Value Stream Improvement Philippines
LEA03 Lean Office: Improving Transactional Processes with Lean Philippines
LEA06 Certified Lean Practitioner Philippines
LEA07 Certified Lean Expert Philippines
LEA08 Certified Lean Master Philippines
LEA11 Total Productive Maintenance (TPM) : Key to Production Effectiveness Philippines
LEA16 Standard Operations with Training Within Industry (TWI) Philippines
LEA18 The A3 Report: A Lean Problem Solving and Reporting Process Philippines
LEA19 An Introduction to Lean Warehousing Philippines
LEA23 Lean Supply Chain Management : Extending the Lean Enterprise Philippines
LEA24 Lean Deployment Management with Hoshin Kanri Philippines
LEA32 Zero Defects Through Poka Yoke Philippines
LEA33 Overall Equipment Effectiveness (OEE) Explained Philippines
LEA34 A Guide to Kaizen Implementation Philippines
Available Dates
Philippines, Manila   2 Days
07-08 October 2019


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