Level Schedule
Definition
A level schedule (production leveling or heijunka) is a production plan that distributes volume and product mix evenly across time periods, so the line builds a stable, repeating pattern instead of large batches that follow demand spikes.
In Practice
Rather than running 2,000 units of A on Monday and 2,000 of B on Thursday, a level schedule might build 400 A and 400 B every day in a repeating mixed sequence. The stable rate lets upstream work centers and suppliers plan to a predictable takt, shrinks the swings that cause the bullwhip effect, and keeps capacity loaded evenly.
Level scheduling is a foundation of just-in-time production: kanban replenishment only works when downstream consumption is reasonably smooth. The trade-off is that the level plan buffers true demand variability with small amounts of finished goods or flexible capacity.
Frequently Asked Questions
What is the difference between a level schedule and a chase strategy?
A level schedule holds the production rate steady and absorbs demand swings with inventory or backlog, while a chase strategy changes output each period to match demand, absorbing swings with overtime, hiring, or idle capacity. Most plants blend the two based on which buffer is cheaper.
Why does lean manufacturing depend on level scheduling?
Kanban and just-in-time replenishment size their loops for a stable consumption rate. If final assembly lurches between big batches, every upstream loop needs oversized buffers to cope. Leveling volume and mix smooths the pull signal, so the whole chain runs with less inventory and shorter lead times.
Related Terms
The pacemaker is the single production process in a value stream that is scheduled directly and sets the pace for everything else — upstream processes replenish to its pull, and downstream steps flow from it in sequence.
Block SchedulingBlock scheduling is a capacity scheduling technique that assigns whole blocks of time — such as a shift, day, or week — to a job or product group at a work center, rather than scheduling exact start and stop times for each operation.
Master Production Schedule (MPS)The Master Production Schedule (MPS) is the anticipated build plan for finished products or key end items, stating what will be produced, in what quantity, and in which time period. It is the primary input that drives MRP.
Lean ManufacturingLean manufacturing is a management philosophy focused on maximizing customer value while systematically eliminating waste, such as excess inventory, waiting, overproduction, and defects.