Expanding to 7 Days

Today, many plants operating on traditional 5-day production schedules are finding it difficult to compete. They may experience significant idle capacity or face the necessity of operating inefficiently with overtime or token crews on the weekends. Moreover, startup and shutdowns only further reduce productivity and efficiency. Sooner or later comes the realization that something must be done and that more efficient utilization of equipment and human assets must be obtained. This can best be accomplished by expanding the plant to a 7-day continuous operation. Unfortunately, such conversions are extremely complex and fraught with pitfalls that can have disastrous consequences if not properly planned and managed. To achieve all of the benefits of continuous operations requires major cultural, organizational, and operational change. This is a huge change for your production employees, - the managers, supervisors, and shiftworkers who will now be required to work through the weekends on a regularly scheduled basis. Many internal support groups are significantly affected as well. While the opportunity to improve financial results, achieve greater asset utilization, defer capital expenditures, and better meet customer needs is alluring, the effect on the people throughout your organization is dramatic. Many problems must be solved before the new ways of working can be accepted.

There are literally thousands of different work patterns in use today to cover working environments that operate around-the-clock, and contrary to popular belief, there is no “perfect schedule” that surpasses all others. The optimal work schedule for any facility consists of a balance between the business needs, sociological needs of the employees, and health and safety needs designed around human factors.

Employee participation in the schedule selection and change process is critical to the initiative’s success. In order for the work schedule to meet the goals of maximizing productivity and safety of the workers and minimizing the operational costs and risks of the facility, employee input must be solicited to insure success in the process.

Facilities in which employees are consulted during the scheduling process, experience fewer accidents, improved morale, decreased absenteeism and turnover, and optimized production levels. Employee-driven scheduling processes, in which operational requirements, employee preferences, and physiological factors are optimized, represent the best approach to designing and implementing new shift schedules.

How CIRCADIAN can help you

CIRCADIAN provides specialized assistance in planning and facilitating 5- to 7-day plant expansions. These support services are designed to help you realize the full benefits of the change, and achieve the desired return-on-investment.

Expanding to 7 Day Operations. CIRCADIAN provides specialized assistance to plan and facilitate 5- to 7-day plant expansions. These support services will help you realize the full benefits of the change, and achieve the desired return-on-investment.
Shift Schedule Optimization. By working with employees, unions, and management, CIRCADIAN develops schedule options that meet the business needs, satisfy worker preferences, and are compatible with human physiology to promote health, safety, and alertness.
Managing a Shiftwork Lifestyle. This on-site training program provides critical information to help employees deal with the challenges of working shiftwork, especially the night shift. Training includes information on fatigue, alertness, sleep, nutrition, health, family/social life and more.