Please note that the content of this book primarily consists of articles available from Wikipedia or other free sources online. Production leveling, also known as production smoothing or – by its Japanese original term – heijunka, is a technique for reducing the muda waste and vital to the development of production efficiency in the Toyota Production System and Lean Manufacturing. The general idea is to produce intermediate goods at a constant rate, to allow further processing to be carried out at a constant and predictable rate. Ideally production can easily be leveled where demand is constant but in the real world where actual customer demand appears to fluctuate two approaches have been adopted in lean: Demand leveling and production leveling through flexible production. On a production line, as in any process, fluctuations in performance increase waste. This is because equipment, workers, inventory and all other elements required for production must always be prepared for peak production. This is a cost of flexibility.

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