When utilizing the eKanban Planner in the Production Module, you are presented with a variety of scheduling methods to facilitate Level Loading (evenly scheduling production to minimize disruptions). Among these options are 'ONCE PER DAY' and 'ONCE PER SHIFT'. These options are self-explanatory.
So, let's dig into 'MINIMAL CHANGEOVERS' and 'HEIJUNKA IDEAL'.
Minimal Changeovers: in a nutshell, utilizing the Minimal Changeovers method allows you to schedule product builds according to the least impactful changeover times between products.
- Product 1 Changeover time = 60 seconds
- Product 2 Changeover time = 120 seconds
- Product 3 Changeover time = 240 seconds
*The least impactful changeovers involve the actual time required to perform that changeover. This may be due to product similarity, therefore requiring fewer or faster material or equipment changes. Scheduling is based on time.
When selecting the Schedule Order by Minimal Changeovers, you will be presented with a modal that give you options:
- Start on/End on: you can select the date range in which to schedule the orders that are visible in the planner. You must have a pitch schedule for the line selected.
- Note: If the product orders cumulative duration based on the Line Cycle times exceed the date range window selected the eKanban planner will prioritize completion of the orders selected and will show completion in hours outside of the pitches scheduled. If you see Scheduled Starts and Scheduled End Dates/Times on days/times that you do not have a pitch schedule, you do not have the available time within the date range and active pitches to complete the order. Reschedule with a larger Start on/End on date range. The eKanban Planner will then schedule the orders across active pitches.
- Schedule By: You can choose by (1) Cycle Time – the system will use the product line cycle time for the line and calculate the duration based on that or (2) Quantity - based on the order quantity and number of pitches.
- Level Loading Method: You can choose by (1) Group by Due Date – the eKanban planner will group like due dates and group/schedule from earliest to latest within the Start On/End on date range or (2) All – the eKanban Planner will schedule in the order of the scheduled start dates.
- Set Pitch Planned Operator from Build Sequence Planned Operator Counts: (1) If checked, the eKanban Planner will use Planned Operator Counts that we selected for the product order, (2) if unchecked, the system will use the default planned operator count for the product line cycle time.
Heijunka Ideal: This method involves scheduling product builds according to Cycle Times, to allow for the most even flow to facilitate level loading.
- Product A Cycle Time = 10 seconds
- Product B Cycle Time = 20 seconds
- Product C Cycle Time = 40 seconds