Heijunka Calculator
Level your production mix: enter daily demand, takt and the number of variants to see units per variant, pitch and the sequence cycle. Free, instant and fully in your browser.
Units per variant
120
per variant per day
Units/variant = demand / variants · pitch = takt
Pitch is the steady beat of one unit (the takt). The sequence cycle is how long it takes to produce the full variant mix once before repeating — keep sequences short to level the load.
What is heijunka?
Heijunka is production levelling: instead of making large batches of one product then switching, you produce a small, repeating mix of all variants in step with demand. Levelling smooths the load on people, machines and suppliers, shrinks inventory and makes flow predictable. It depends on short changeovers (SMED) and a steady takt, and it turns lumpy customer orders into a calm, repeatable rhythm on the floor.
How to level production
- 1
Know your demand and mix
Take total daily demand across all variants and count how many distinct variants share the line.
- 2
Set the takt
Takt time is net available time divided by total demand — the beat each unit must follow.
- 3
Build the level sequence
Units per variant and the sequence cycle tell you how to interleave variants into a short, repeating pattern that matches demand.
Frequently asked questions
What does heijunka require to work?
Short changeover times are essential — levelling means switching variants often, so SMED is a prerequisite. A stable takt and reliable processes also matter, since levelling exposes variability.
What is pitch?
Pitch is the management time increment for a level schedule — here the takt for one unit. On a heijunka box it is often a pack-out quantity's worth of takt, used to pace material release and check progress.
How does Yamazo Studio help?
Levelling needs short changeovers. Yamazo Studio analyses changeover work from video (SMED) and builds standard work, so switching variants quickly becomes routine and levelling becomes practical.
Related lean tools
Level the mix with faster changeovers
Heijunka works when changeovers are quick. Yamazo Studio turns changeover video into SMED analysis and standard work — one offline Lean Operating Desk.
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