Let us explore two possible heijunk

Let us explore two possible heijunka options. The first option uses leveled mixed-model assembly,producing a mix of models in smaller lots. Note that the production requirements at Toyota are in the ratio of 4 Cs to 3 As to 2 Vs, found by dividing the model’s production requirements by the greatest common divisor, or 50. Thus, the Toyota planner could develop a production cycle consisting of 9 units:4 Cs, 3 As, and 2 Vs. The cycle would repeat in 911.0672 = 9.60 minutes, for a total of 50 times per shift 1480 min/9.60 min = 502.The second heijunka option uses a lot size of one, such as the production sequence of C–V–C– A–C–A–C–V–A repeated 50 times per shift. The sequence would achieve the same total output as the other options; however, it is feasible only if the setup times are brief. The sequence generates a steady rate of component requirements for the various models and allows the use of small lot sizes at the feeder workstations. Consequently, the capacity requirements at those stations are greatly smoothed. These requirements can be compared to actual capacities during the planning phase, and modifications to the production cycle, production requirements, or capacities can be made as necessary