Level Schedule

Heijunka = creating  level schedule by sequencing orders in a repetitive pattern, and smoothing the day-to-day variations in total orders to correspond to long-term demand.

How?

Calculate total orders per product family for a time period (e.g. a week), and then create a schedule to "make a little of everything  every day".

Example: This week's customer orders for product line A are 400 and product line B are 600.

If your change-over set-up times are still a problem, you might plan to make Product A on Monday and Tuesday, and Product B on Wednesday, Thursday, and Friday.

If you are able to reduce set-up times, you might make product A every morning and product B every afternoon.

If you can reduce your setup times to be a non-factor, then you would plan to make 2 A's followed by 3 B's all day long.