Shift Roaster for Covering 24X7 Operations

Once the business starts growing, the next challenge for manufacturing organisation is to convert operations into 3 shift operations. Electronics Industry being a heavy Capex industry also demand utilisation of all the equipments and investments for 3 shifts so that the relevant ROI can be achieved from capital investment.

Once the business pick up further, there will be requirements of running 24 hours and also on weekends. A detailed planning is required to execute 24X7 coverage through out the year. This is how , it can be achieved.

• Hire 3 set of crews. Each crew should be able to manage operations independently.
• All the people working on shop floor must be willing to work in day and night shifts as per the schedule. In some states or countries, females cannot work during night shifts in manufacturing environment. Organisation in this case, need to hire only male operators.
• Supervisors accountable for shift operations covering quantity, quality and discipline also needs to be part of the crew. There must be a shift supervisor covering each shift.
• The skill levels to be made available according to the requirements in each shift.
• All the operators will work for 12 hours in a day for 4 days and then take an off for 2 days.
• Operator working in morning shift for 4 days will come back in night shift after 2 days off.
• Operators working in night shift will come back in day shift after 2 days off.

Attached is the detailed visual on how operators need to be rotated in this shift patter.

While this plan looks very easy on paper, but in execution it comes up with various challenges. Here is a step by step guide for implementing this plan

1. Develop a Shift Schedule

• Rotating Shifts: Implement rotating shifts (e.g., morning and night) to distribute the workload evenly and prevent employee burnout.
• Overlap Periods: Incorporate overlap periods of 10 minutes between shifts to allow for smooth transitions and handovers.

2. Cross-Train Employees

• Train employees to perform multiple roles or operate different machines. This increases flexibility, allowing employees to fill in gaps during absences or emergencies.
• Cross-training also reduces dependency on a limited number of skilled workers.

3. Implement Technology and Automation

• Use automation tools and machinery to maintain consistent production quality and efficiency, especially during night shifts.
• Implement predictive maintenance systems to minimize downtime and ensure machines run efficiently during all shifts.

4. Set Up Clear Communication Protocols

• Use digital tools, such as shift management apps or intranet portals, to share schedules, updates, and reports across teams.
• Encourage proper documentation and handovers at the end of each shift to ensure continuity.

5. Create an Employee-Friendly Shift Policy

• Provide adequate breaks and rest periods between shifts to comply with labor laws and avoid fatigue.
• Make sure the shift schedules are fixed and transparent to all the employees. Everyone working on shop floor must be treated equally.

6. Monitor Employee Wellness

• Conduct regular wellness checks to ensure employees working rotating or night shifts are not facing long-term health issues.
• Offer amenities such as cafeterias, rest areas, or transportation services for late-night employees.

7. Encourage Continuous Feedback

• Collect regular feedback from employees regarding shift policies and work environment.
• Adapt schedules and processes based on employee suggestions to improve satisfaction and productivity.

8. Track Performance Metrics

• Monitor key performance indicators (KPIs) for each shift, such as output, quality, and efficiency.
• Analyze data to identify trends and optimize processes during specific shifts.

If you have any questions or queries on this subject, please reach out to me and would be happy to answer these queries.