Load leveling is key to becoming lean

The last few posts on our blog focussed on Value Stream Mapping and other lean tools used for waste removal.
Removing waste is the main focus of lean manufacturing.
Value Stream Maps allow lean practitioners to get a true picture of activities done in a process. These maps make waste visible so that it can be removed.
Waste can be removed using lean tools.

In today's world, production volumes change based on customer demand and customer demand fluctuates. Plants practicing Just In Time start producing only when the customer signals for parts. Plants cannot possibly respond to such high variations in demand. So they carry some buffer stock for finished goods.
There may be raw material inventory or WIP necessary to prepare for such demand fluctuations.

Carrying enough inventory is the key to meet customer demands. If plants carry too much they are creating waste and hiding problems.
That is why it is important to level the load so that plants produce at a uniform pace without causing stress to equipment or people. Stressing the equipment could cause breakdowns and stressing people may cause errors or accidents.

But what is load leveling?
Load Leveling is the process of producing the same quantity and mix of parts without responding to every fluctuation in customer demand. This reduces unnecessary stress on equipment or people working in the plant resulting in fewer breakdowns and errors.

The question is how to level the load?
We will try to answer this in our next post.