Module 7 · Lesson 20 of 24
Heijunka and production levelling
This lesson and the entire Lean Six Sigma Black Belt academy are free of charge — no fees, ever.
Learning objectives
- Explain the purpose of heijunka and production levelling in garment operations.
- Describe when and how to apply heijunka and production levelling on the shop floor.
- Identify common mistakes and how to avoid them.
Core idea
Heijunka levels volume and mix over a practical horizon to reduce peaks, queues, firefighting and uneven resource demand.
Method
Stabilize demand window, choose pitch, group compatible products, design level box/sequence, protect frozen zone and exceptions. Do not level beyond supply and process flexibility.
Garment-factory example
Sequence style/colour families in small repeatable increments while respecting due dates, changeover, fabric availability and skill.
Method
- Stabilize demand window, choose pitch, group compatible products, design level box/sequence, protect frozen zone and exceptions
Common mistakes
- Do not level beyond supply and process flexibility
Knowledge check
Pick one answer per question. Explanations appear after you submit.
1. Which statement best captures the core idea of Heijunka and production levelling?
2. A common mistake when applying heijunka and production levelling is to:
Author: NOSK.life · Last reviewed: 2026-07-21