HEIJUNKA (PRODUCTION LEVELING) IMPLEMENTATION CHECKLIST

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--- PHASE 1: ASSESSMENT & PREPARATION ---
[ ] Describe the current production environment (e.g., make-to-stock, make-to-order, mixed).
[ ] Estimate the current level of production variability (e.g., using a scale of 1-10, 1 being very stable, 10 being extremely variable).
[ ] Identify the primary goals of Heijunka implementation (Select all that apply). (Reduce lead time, Reduce WIP (Work in Progress), Reduce inventory, Improve throughput, Level workload, Improve customer satisfaction, Other (Please Specify))
[ ] Identify key stakeholders for Heijunka implementation and their roles.
[ ] What are the current challenges that contribute to production instability? (Select all that apply) (Demand Fluctuations, Long Setup Times, Material Shortages, Equipment Downtime, Lack of Standardized Processes, Poor Communication, Other (Please Specify))
[ ] Target Date for Initial Heijunka Assessment Completion
[ ] Document potential resistance to change and strategies for addressing it.

--- PHASE 2: DATA GATHERING & ANALYSIS ---
[ ] Historical Demand Data Collection Period (Months)
[ ] Upload Historical Sales Data (CSV/Excel)
[ ] Describe Data Sources Used (e.g., ERP, CRM, spreadsheets)
[ ] Number of Product Families/Lines to Analyze
[ ] Which Demand Patterns Observed (Select all that apply) (Seasonal, Trend, Cyclical, Random/Unpredictable, Lumpy/Irregular)
[ ] Average Lead Time for Raw Materials (Days)
[ ] Current WIP (Work-In-Progress) Levels (Units)
[ ] Describe any significant external factors impacting demand (e.g., promotions, competitor actions)

--- PHASE 2A: DEMAND FORECASTING & SEGMENTATION (IF APPLICABLE) ---
[ ] Historical Demand Data Points Analyzed (Months/Years)
[ ] Forecasting Methods Considered/Implemented (Moving Average, Exponential Smoothing, Regression Analysis, Seasonal Decomposition, Collaborative Forecasting (Sales/Marketing))
[ ] Primary Demand Segmentation Criteria (Product Family, Customer Type, Geographic Region, Order Size/Volume, Seasonality)
[ ] Forecast Accuracy (MAPE - Mean Absolute Percentage Error) - Baseline
[ ] Forecast Accuracy (MAPE - Mean Absolute Percentage Error) - Post-Segmentation/Forecasting
[ ] Justification for Selected Segmentation Criteria
[ ] Level of Customer Collaboration in Forecasting (None, Informal Communication, Regular Meetings, Shared Forecasts)

--- PHASE 3: HEIJUNKA DESIGN & PLANNING ---
[ ] Calculate Current Takt Time
[ ] Determine Initial Heijunka Sequence Type (e.g., Fixed Sequence, Dynamic Sequence) (Fixed Sequence, Dynamic Sequence, Hybrid)
[ ] Establish Initial Batch Sizes (considering changeover time and inventory costs)
[ ] Document Rationale for Batch Size Decisions
[ ] Calculate Changeover Times for all Product Variations
[ ] Define Buffer Strategy (e.g., Supermarket, Kanban) (Supermarket, Kanban, None)
[ ] Calculate Minimum Buffer Levels (based on variability and takt time)
[ ] Describe the Heijunka Schedule Logic (how production is sequenced)

--- PHASE 4: PILOT IMPLEMENTATION & TESTING ---
[ ] Select Pilot Production Line (Line 1, Line 2, Line 3, Other (Specify))
[ ] Pilot Duration (in days)
[ ] Describe the initial scope of the pilot Heijunka implementation (e.g., products, processes)
[ ] Which metrics will be tracked during the pilot? (Throughput, Work-in-Progress (WIP), Lead Time, Inventory Levels, On-Time Delivery, Employee Morale (via survey))
[ ] Pilot Start Date
[ ] Pilot End Date (Planned)
[ ] Document any significant challenges encountered during the pilot.
[ ] Overall Pilot Success (Initial Assessment) (Highly Successful, Successful, Moderately Successful, Unsuccessful - Requires Major Revision, Unsuccessful - Requires Complete Re-evaluation)
[ ] Upload relevant data/charts from the pilot (optional)

--- PHASE 5: FULL-SCALE IMPLEMENTATION ---
[ ] Initial Product Line Rollout Sequence (Priority 1 (High Volume, Low Variability), Priority 2 (Moderate Volume, Moderate Variability), Priority 3 (Lower Volume, High Variability))
[ ] Scheduled Start Date for Full-Scale Implementation
[ ] Number of Production Lines Initially Included
[ ] Describe any deviations from the original Heijunka design plan during full-scale rollout.
[ ] Which departments are actively participating in the full-scale rollout? (Production, Engineering, Sales/Demand Planning, Quality, Supply Chain)
[ ] Level of Automation used in initial rollout. (Manual, Semi-Automated, Fully Automated)
[ ] Contact Person for Full-Scale Implementation
[ ] Document any initial training provided to employees during full-scale launch.

--- PHASE 6: MONITORING & CONTINUOUS IMPROVEMENT ---
[ ] Average Daily Production Variation (compared to target)
[ ] On-Time Delivery Performance (OTD)
[ ] Work-in-Progress (WIP) Inventory Levels
[ ] Overall team satisfaction with the Heijunka system (Very Satisfied, Satisfied, Neutral, Dissatisfied, Very Dissatisfied)
[ ] Summarize key observations and issues encountered during the monitoring period.
[ ] Which metrics are showing a concerning trend? (Production Variation, On-Time Delivery, WIP Inventory, Lead Time, Equipment Downtime, None)
[ ] Date of last Heijunka Review Meeting
[ ] Document Action Items and assigned owners resulting from the review

--- SUPPORTING INFRASTRUCTURE & TRAINING ---
[ ] Current Level of Kanban System Usage (if applicable) (No Kanban, Basic Kanban, Advanced Kanban (with automated replenishment))
[ ] Systems/Tools to be Integrated with Heijunka (select all that apply) (ERP System, MES System, MRP System, Quality Management System, Production Scheduling Software)
[ ] Number of Employees Requiring Initial Heijunka Training
[ ] Target Date for Initial Heijunka Training Completion
[ ] Training Program Outline (brief description)
[ ] Training Delivery Method (select one) (Classroom, Online Modules, On-the-Job Training)
[ ] Training Materials (presentations, guides, etc.)
[ ] Documented Standard Operating Procedures (SOPs) for Heijunka Processes (describe)
[ ] Availability of Visual Management Tools (e.g., whiteboards, displays) (Not Available, Limited Availability, Fully Available)

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