Module 8 · Lesson 6 of 29

Principle 4: level the workload

Learning objectives

Explain the purpose of principle 4: level the workload in garment operations.
Describe when and how to apply principle 4: level the workload on the shop floor.
Identify common mistakes and how to avoid them.

Reduce unevenness and overburden by levelling demand/mix and designing humane, stable work.

Analyze demand and capacity; define frozen window and flex plan; monitor fatigue/quality. Levelling must not hide true customer volatility.

Smooth style introductions, overtime, maintenance and skill allocation across the production horizon.

Pick one answer per question. Explanations appear after you submit.

1. Which statement best captures the core idea of Principle 4: level the workload?
- Reduce unevenness and overburden by levelling demand/mix and designing humane, stable work.
- It is a purely financial control unrelated to shop-floor work.
- It replaces the need for standardized work and training.
- It applies only to fully automated factories.
2. A common mistake when applying principle 4: level the workload is to:
- Levelling must not hide true customer volatility
- Involve operators and validate with data.
- Link the tool to the observed problem and follow-up plan.
- Update the standard after a confirmed improvement.

Author: Sanjeewa Dehiwalage · Last reviewed: 2026-07-21