What is a pitch increment?

One slot in the heijunka box, and one release interval. The box holds as many slots as the shift has increments, so the increment count and the pitch interval divide the same available time.

How do I choose the number of increments?

From the handling and changeover rhythm you can sustain: more increments mean smaller, more frequent releases. Then check units per pitch stays at one or more; demand sets the upper limit.

Why level production by quantity as well as type?

Because a wave of one model empties buffers upstream and starves processes downstream. Spreading units evenly across the shift keeps every process pulling at the same pace and exposes the real capacity limit.

Does takt change when the increment count changes?

No. Takt comes from available time and demand only, so it stays fixed while you rebalance the box. Use the takt row as the check that each pitch still holds enough work.

Lean Manufacturing & Operations calculator

Heijunka Leveling Pitch Calculator

Level a shift by dividing its available time into pitch increments and its demand across them. You need available time per shift, the number of increments and the shift demand.

What this calculator does

Heijunka pitch interval and the level quantity each pitch builds from shift time, increments and demand.

Formula used

Pitch interval = available time per shift ÷ pitch increments per shift
Units per pitch = demand per shift ÷ pitch increments per shift
Takt time = available time per shift ÷ demand per shift
Required rate = demand per shift ÷ available time per shift × 60

Inputs explained

Available Time per Shift: Run time per shift after breaks and planned downtime.
Pitch Increments per Shift: Slots in the heijunka box per shift.
Demand per Shift: Units the line must ship in the shift.

How to use the result

Best suited to setting a mixed-model pitch box, levelling a shift after a demand rise, checking whether increments fit demand.
Level quantity assumes the mix can be sequenced freely; a long setup between models breaks the rhythm. A demand rate that changes mid-shift needs the box rebalanced, not just the pitch recalculated.

Current U.S. benchmarks

U.S. manufacturing runs at 75.7% of capacity (Federal Reserve, Aug 2026). New factory orders are up 8.5% year over year (Census).

Common questions

What is a pitch increment? One slot in the heijunka box, and one release interval. The box holds as many slots as the shift has increments, so the increment count and the pitch interval divide the same available time.
How do I choose the number of increments? From the handling and changeover rhythm you can sustain: more increments mean smaller, more frequent releases. Then check units per pitch stays at one or more; demand sets the upper limit.
Why level production by quantity as well as type? Because a wave of one model empties buffers upstream and starves processes downstream. Spreading units evenly across the shift keeps every process pulling at the same pace and exposes the real capacity limit.
Does takt change when the increment count changes? No. Takt comes from available time and demand only, so it stays fixed while you rebalance the box. Use the takt row as the check that each pitch still holds enough work.

Last reviewed 2026-10-01.