Heijunka: Fast like a Tortoise

In the third chapter, we will continue to approach the core topic of variable takt and VarioTakt. This section is once again intended as a basic chapter to generate a broad and deep understanding of the balancing of flow assemblies. It focuses on elements of Sequence Design for Mixed-Model Assembly (SD for MMA) from our MMAD model. As before, in this part, we will try to combine the approaches of the scientific literature on levelling with management-oriented practical knowledge on Heijunka to generate added value. We will show that the origins of Heijunka can be found in Toyota’s Lean Management philosophy and thus form the basis for almost every production system used today. In parallel, levelling has been and continues to be a focus of much scientific work in the field of Operations Research. It will become apparent that variable takt complements existing concepts for levelling production quite decisively and creates a self-levelling production system. For example, VarioTakt takes on the task of regulating overload situations in an assembly line without intervening in the series-sequence. As a result, series-sequence planning could be focused exclusively on supply levelling—or true build-to-order production could be implemented (Fig. 3.1).