Heijunka Module Configuration

Steps to configure the Heijunka Module

1. Enable the Heijunka Module

Ask the KanbanBOX Support team to enable for you the module from the back-end.

2. Configure the company-wide settings of Heijunka

In Settings > Company Settings, Heijunka section, configure the Heijunka Board. Now you can access the "Automatic levelling" and "Manual levelling" pages, but they are still empty.

3. Add Suppliers to Heijunka

In the Partner Master, edit each partner that needs to appear in the Heijunka Board:

• Enable Heijunka must be Yes.
• Select the working intervals in which the Partner should be considered active.

Now the Partners appear in the "Automatic levelling" page, and part numbers having those partners as supplier appear in the "Manual levelling" page.

4. Create the Heijunka Boards that you need

For each separate Heijunka Board you want to have:

1. In the "Manual levelling" page, filter the partners you want to see in the specific Heijunka board, and save the filter.
2. From Settings > Custom actions, add an action with function "Create and print Heijunka worklist" and the filter you have just created. Fill in the appearance fields as you prefer, they are currently not used.

Additional configurations

Ask the KanbanBOX Support team to change the demand window settings, if needed.

Demand window and Levelling window

Levelling Window is the time window on which the algorithm levels the production in one run. By default, the Levelling Window corresponds to one calendar week, as this is the most common way heijunka processes are implemented.

Demand Window is the time range of required dates that tell the levelling algorithm which cards should be levelled in each levelling window. By default, the demand window is equal to the levelling window (each week, the algorithm levels cards that are required for the same week).

The Demand Window can be customized by the KanbanBOX Support team, configuring an offset from the default value by the settings:

• ext_heijunka_demand_window_start_offset (example: "-1 year")
• ext_heijunka_demand_window_end_offset (example: "+1 year")

Algorithms

Level Mix

Cards are levelled on each pitch interval by cards count, part numbers are as mixed as possible.

Example:

Demand:
*  50 cards of A
*  25 cards of B
*  25 cards of C

Result:
|A B A C A B A C ... A B A C|

Level Batches

Cards are levelled by cards count, part numbers are sequenced in batches.

Priority of the part number is calculated by the largest batch.

Example:

Demand:
*  50 cards of A
*  25 cards of B
*  25 cards of C

Result:
|A A A A A A A A ... B B B B ... C C C C|

Sequence Batches (by capacity)

Cards are sequenced in batches, considering finite capacity and optional setup.

Priority of the part number is calculated as:

• Value of Kanban Custom field 1, in ascending order, to define a fixed sequence
• Part number, in ascending order

An optional setup time, expressed in seconds, can be added to: * Custom field 1 in the partner master, as a standard setup for the Supplier * Kanban Custom field 2 in the loop table, as a setup specific for the kanban loop

Example:

Demand:
*  10 cards of A
*  5 cards of B
*  5 cards of C

Result:
|(setup)AAAAAAAAAA(setup)BBBBB(setup)CCCCC________________|

Sequence Dates and Batches (by capacity)

Similar to "Sequence Batches", with a change in how priority is calculated. Cards are sequenced in batches, considering finite capacity and optional setup.

Priority of the part number is calculated as:

• Earliest Required Date
• Value of Kanban Custom field 1, in ascending order, to define a fixed sequence
• Part number, in ascending order

An optional setup time, expressed in seconds, can be added to: * Custom field 1 in the partner master, as a standard setup for the Supplier * Kanban Custom field 2 in the loop table, as a setup specific for the kanban loop

Example:

Demand:
*  10 cards of A
*  5 cards of B
*  5 cards of C

Result:
|(setup)AAAAAAAAAA(setup)BBBBB(setup)CCCCC________________|