Research On Heijunka Production In Discrete Manufacturing Based On TPS

Due to the rapidly changing and the increasingly fierce competition in themarket, many small and medium-sized enterprises are faced with more pressurewith lower cost, shorter cycle and higher quality than in the past.To solve the aboveproblems, it was key studied on Heijunka of the Toyota Production System(TPS)and research achievements were applied in specific case which not only offeredimportant theory references, but also provided a model of the concrete practice ofthe activities for enterprise.Firstly, four new changes of TPS were discussed, including the changes ofcognitive, the changes of production, the changes of manpower and the changes ofmanagement, TPS was proved to be an advanced mode of management.Secondly, Heijunka system was constructed in order to provide importantguidance and basis for small and medium enterprises, which included the balanceof production line, the reasonable sequence for multi-products, the layout of theproduction line, training of multi-skilled staff，the standard operation procedure andquality management.Finally, Heijunka was applied in an enterprise. Through the implementation ofthe “Bus Run” logistics and distribution integration planning, Optimized oflogistics channel and labor costs were reduced and efficiency was improved;through the use of genetic algorithm for the arrangements of the variety of products,operating time was reduced greatly.Practice demonstrates that Heijunka can increase the equilibrium rate,efficiency of working procedures and reduce goods in process. So that it is possibleto make the maximum output (high quality product， high productivity and low cost， highcustomer satisfaction，etc) with the minimum input (personnel，equipment and materials，etc) for enterprises, which will get a better space for development in the fierce marketcompetition.