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| Phase 1: Assessment & Preparation (STEP) | | |
| Describe the current production environment (e.g., make-to-stock, make-to-order, mixed). (TEXT) | | |
| Estimate the current level of production variability (e.g., using a scale of 1-10, 1 being very stable, 10 being extremely variable). (NUMBER) | | |
| Identify the primary goals of Heijunka implementation (Select all that apply). (SELECTION options: 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. (TEXT) | | |
| What are the current challenges that contribute to production instability? (Select all that apply) (SELECTION options: 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 (DATE) | | |
| Document potential resistance to change and strategies for addressing it. (TEXT) | | |
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| Phase 2: Data Gathering & Analysis (STEP) | | |
| Historical Demand Data Collection Period (Months) (NUMBER) | | |
| Upload Historical Sales Data (CSV/Excel) (UPLOAD) | | |
| Describe Data Sources Used (e.g., ERP, CRM, spreadsheets) (TEXT) | | |
| Number of Product Families/Lines to Analyze (NUMBER) | | |
| Which Demand Patterns Observed (Select all that apply) (SELECTION options: Seasonal, Trend, Cyclical, Random/Unpredictable, Lumpy/Irregular) | | |
| Average Lead Time for Raw Materials (Days) (NUMBER) | | |
| Current WIP (Work-In-Progress) Levels (Units) (NUMBER) | | |
| Describe any significant external factors impacting demand (e.g., promotions, competitor actions) (TEXT) | | |
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| Phase 2a: Demand Forecasting & Segmentation (if applicable) (STEP) | | |
| Historical Demand Data Points Analyzed (Months/Years) (NUMBER) | | |
| Forecasting Methods Considered/Implemented (SELECTION options: Moving Average, Exponential Smoothing, Regression Analysis, Seasonal Decomposition, Collaborative Forecasting (Sales/Marketing)) | | |
| Primary Demand Segmentation Criteria (SELECTION options: Product Family, Customer Type, Geographic Region, Order Size/Volume, Seasonality) | | |
| Forecast Accuracy (MAPE - Mean Absolute Percentage Error) - Baseline (NUMBER) | | |
| Forecast Accuracy (MAPE - Mean Absolute Percentage Error) - Post-Segmentation/Forecasting (NUMBER) | | |
| Justification for Selected Segmentation Criteria (TEXT) | | |
| Level of Customer Collaboration in Forecasting (SELECTION options: None, Informal Communication, Regular Meetings, Shared Forecasts) | | |
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| Phase 3: Heijunka Design & Planning (STEP) | | |
| Calculate Current Takt Time (NUMBER) | | |
| Determine Initial Heijunka Sequence Type (e.g., Fixed Sequence, Dynamic Sequence) (SELECTION options: Fixed Sequence, Dynamic Sequence, Hybrid) | | |
| Establish Initial Batch Sizes (considering changeover time and inventory costs) (NUMBER) | | |
| Document Rationale for Batch Size Decisions (TEXT) | | |
| Calculate Changeover Times for all Product Variations (NUMBER) | | |
| Define Buffer Strategy (e.g., Supermarket, Kanban) (SELECTION options: Supermarket, Kanban, None) | | |
| Calculate Minimum Buffer Levels (based on variability and takt time) (NUMBER) | | |
| Describe the Heijunka Schedule Logic (how production is sequenced) (TEXT) | | |
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| Phase 4: Pilot Implementation & Testing (STEP) | | |
| Select Pilot Production Line (SELECTION options: Line 1, Line 2, Line 3, Other (Specify)) | | |
| Pilot Duration (in days) (NUMBER) | | |
| Describe the initial scope of the pilot Heijunka implementation (e.g., products, processes) (TEXT) | | |
| Which metrics will be tracked during the pilot? (SELECTION options: Throughput, Work-in-Progress (WIP), Lead Time, Inventory Levels, On-Time Delivery, Employee Morale (via survey)) | | |
| Pilot Start Date (DATE) | | |
| Pilot End Date (Planned) (DATE) | | |
| Document any significant challenges encountered during the pilot. (TEXT) | | |
| Overall Pilot Success (Initial Assessment) (SELECTION options: Highly Successful, Successful, Moderately Successful, Unsuccessful - Requires Major Revision, Unsuccessful - Requires Complete Re-evaluation) | | |
| Upload relevant data/charts from the pilot (optional) (UPLOAD) | | |
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| Phase 5: Full-Scale Implementation (STEP) | | |
| Initial Product Line Rollout Sequence (SELECTION options: 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 (DATE) | | |
| Number of Production Lines Initially Included (NUMBER) | | |
| Describe any deviations from the original Heijunka design plan during full-scale rollout. (TEXT) | | |
| Which departments are actively participating in the full-scale rollout? (SELECTION options: Production, Engineering, Sales/Demand Planning, Quality, Supply Chain) | | |
| Level of Automation used in initial rollout. (SELECTION options: Manual, Semi-Automated, Fully Automated) | | |
| Contact Person for Full-Scale Implementation (TEXT) | | |
| Document any initial training provided to employees during full-scale launch. (TEXT) | | |
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| Phase 6: Monitoring & Continuous Improvement (STEP) | | |
| Average Daily Production Variation (compared to target) (NUMBER) | | |
| On-Time Delivery Performance (OTD) (NUMBER) | | |
| Work-in-Progress (WIP) Inventory Levels (NUMBER) | | |
| Overall team satisfaction with the Heijunka system (SELECTION options: Very Satisfied, Satisfied, Neutral, Dissatisfied, Very Dissatisfied) | | |
| Summarize key observations and issues encountered during the monitoring period. (TEXT) | | |
| Which metrics are showing a concerning trend? (SELECTION options: Production Variation, On-Time Delivery, WIP Inventory, Lead Time, Equipment Downtime, None) | | |
| Date of last Heijunka Review Meeting (DATE) | | |
| Document Action Items and assigned owners resulting from the review (TEXT) | | |
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| Supporting Infrastructure & Training (STEP) | | |
| Current Level of Kanban System Usage (if applicable) (SELECTION options: No Kanban, Basic Kanban, Advanced Kanban (with automated replenishment)) | | |
| Systems/Tools to be Integrated with Heijunka (select all that apply) (SELECTION options: ERP System, MES System, MRP System, Quality Management System, Production Scheduling Software) | | |
| Number of Employees Requiring Initial Heijunka Training (NUMBER) | | |
| Target Date for Initial Heijunka Training Completion (DATE) | | |
| Training Program Outline (brief description) (TEXT) | | |
| Training Delivery Method (select one) (SELECTION options: Classroom, Online Modules, On-the-Job Training) | | |
| Training Materials (presentations, guides, etc.) (UPLOAD) | | |
| Documented Standard Operating Procedures (SOPs) for Heijunka Processes (describe) (TEXT) | | |
| Availability of Visual Management Tools (e.g., whiteboards, displays) (SELECTION options: Not Available, Limited Availability, Fully Available) | | |