We all know shift management can get messy. The degree of it varies from industry to industry. But how messy it can be in the manufacturing sector. Wait a minute. Isn’t not the same as in other sectors like healthcare, logistics, IT or construction? Can’t shift management software address it?

Well, every sector poses its challenges when planning rosters for the team. But, the manufacturing sector specifically has some challenges. For instance, machinery downtime, and production line dependency to name a few. Hence, when managers design shift plans, they need to take account of these nuances so that operations are not going to be affected. In this blog, let’s analyse

• Common shift scheduling challenges in the manufacturing sector
• Types of shift patterns used in manufacturing operations
• Tips to optimize schedules in manufacturing via shift management software

Common Shift Scheduling Challenges in the Manufacturing Sector

By partnering with numerous manufacturing businesses, we have identified the following challenges that business leaders in this sector commonly face.

Machinery Downtime:

There is a certain level of unpredictability in the manufacturing sector. When equipment fails unexpectedly, production has to be halted. As a manager, you need to account for these downtimes when creating schedules on shift management software. Scheduling maintenance during periods of low production volume or demand can help minimize the associated costs.

Production Line Dependency:

In manufacturing, problems in one part of the process can disrupt the whole production line, so minimizing the level of loss from such dependency-related halts is crucial. Managers need to identify, map, and prioritize dependencies in the manufacturing process.

In high-dependency situations, put responsible people in charge to account for and track any downtime. Establishing a contingency plan to address last-minute changes and communicating these changes in real-time via shift management software can help maintain uninterrupted operations and minimize the impact of production-line dependencies.

Variable Workload Level:

A consistent product demand rarely matches your planned goals. Market trends and seasonal changes create unexpected fluctuations. You need to avoid overstaffing when production volume is low. Similarly, staff shortages can disrupt workflow when production volume is high.

It's crucial to maintain a balanced workforce that matches your variable workload. A modern employee shift management system can help - it lets you adjust shifts quickly and notify employees of changes immediately.

Following labour compliance guidelines:

Businesses in the manufacturing sector need to ensure strict adherence to labour compliance guidelines. Since the physical strain of the work is high, adjusting working hours and breaks to prevent employee fatigue is essential.

However, what will you do when there is occasional or seasonal high production demand? While this can be tricky, it is best addressed by using an online shift management system that allows for flexible, frequent shift adjustments to accommodate changing needs.

Skilled Labour Shortages:

Manufacturing companies often face the challenge of sourcing a sufficient number of employees who meet the required competencies per shift. For instance, for handling specialized roles such as CNC machinists. Although overtime work or temporary employment can help plug these gaps, both have their downsides.

Overtime may result in exhaustion and reduced productivity levels whereas temporary workers may prove to be inadequate for undertaking advanced tasks, which may lead to mistakes and delays. This thus, underscores the need for accurate workforce planning and optimized scheduling with shift management software. This way, one can ensure optimal resource utilization vis-a-vis the production requirements.

Types of Shift Patterns Used In Manufacturing

The manufacturing industry relies on different shift patterns to keep its operations running. What style you can choose for your operation ultimately depends on what your priorities are and whether your shift management software allows it. Here are some of the frequent choices.

Fixed Shifts:

Fixed shifts are the most common shift pattern choice among several manufacturing entities. The company sets a fixed shift, for instance, starting at 8 am and ending at 5 pm with a set time for breaks. These types of shifts are mostly preferred by companies which have consistent and steady production schedules.

DuPont Shift:

The American multinational Chemical company DuPont de Nemours Inc. is credited for introducing the DuPoint shift. It has since become a popular shift pattern used by several manufacturing companies across the world.

The DuPont shift plan runs over four-week cycles. Workers put in 12-hour shifts. They switch between days and nights, with days off in between. This setup helps keep the factory running non-stop while giving workers enough time to rest. In an ideal scenario with four teams and a four-week cycle, Team A will work according to the following table.

Example schedule for Team A :

Rotating Shifts:

In rotating shifts, employees rotate through different schedules over a fixed period. For instance, one week on the morning shift, the next week on the evening shift, and the following week on the graveyard (night) shift.

Of course, some employees love certain shifts and dislike the rest. However, the shift management software prepares rotating shifts evenly and ensures that every staff member gets their desirable or non-desirable shifts.

Split shifts:

Split shifts are common in manufacturing and other sectors with peak production demands during specific times, such as early morning and late evening. This is particularly prevalent in food and beverage manufacturing, like milk packaging factories. They cannot pre-produce large quantities of goods for future distribution. Due to their short shelf life, products must be distributed immediately after packaging.

To address this, they divide employees' shifts into four-hour morning and evening segments, separated by a long break. This approach helps avoid production interruption while maintaining adequate staffing levels.

Compressed workweek:

Recent reports show that compressed workweek is becoming increasingly popular in several industries including manufacturing. So, many emerging shift management software providers make it a point to add this shift pattern to the functionality. Here, employees work longer hours each day to meet their 40-hour weekly quote. So, rather than five 8-hour work days, they work four 10-hour work days. The factory may remain closed for three weekly offs.

The advantage is that employees get three days off to do their personal needs. The company can remain closed for three days to minimize operational expenses. However, implementing a compressed workweek in manufacturing can be challenging. It is only feasible where batch production is done. For instance, in electronics manufacturing, especially in assembly line operations.

Weekend shift:

Weekend shifts allow employees to work exclusively on weekends, which can be beneficial for 24/7 operations that demand additional coverage. This approach is particularly helpful for students who can balance their studies with weekend work, and earn extra income while gaining experience in the manufacturing sector.

Meanwhile, regular employees can enjoy traditional weekend off or opt to work on weekends and use weekdays for personal commitments that cannot be addressed during the weekend.

Best Practices for Optimizing Shifts in Manufacturing Operations

The smooth running of your manufacturing operations is directly linked to how efficiently you are managing your employees’ work schedules on your shift management software. Here are some proven best practices for optimizing shifts in manufacturing operations.

Analyse business targets and demand cycles:

Shift management is not merely about filling vacant spots on the shift schedule. It must align with business objectives and demand cycles. Each shift requires experienced and capable staff to handle specific production duties, not just any employees to meet a headcount.

Historical shift data from shift management software reports can be instrumental in this regard. By comparing more effective shifts with less effective ones, valuable insights can be gained.

Utilize shift management software for efficiency:

How are you scheduling your employees? If you're relying on a manual process, such as spreadsheets, it's likely less effective and prone to errors. In the manufacturing sector, dynamic shift management is crucial.

Shifts often change, and you can't always rely on manual processes to ensure timely completion of work. Consider adopting a modern, flexible, and integrated shift management software to streamline this process.

Design flexible shift patterns:

When planning your workforce schedule, it's important to design flexible shift patterns that can adapt to changing demands. You can use approaches like rotating shifts or split shifts to keep productivity high while still considering what works for your employees.

Speaking of employees, it's really valuable to ask them about their shift preferences - this not only keeps them happier in their jobs but also helps maximize their contributions.

Plan ahead for possible disruptions:

It's crucial to stay prepared for the unexpected in your workforce management, especially when it is in the manufacturing domain. One effective strategy is training your team members to handle different roles in your production process.

This way, you'll have much more flexibility when someone calls in sick or during sudden staff shortages. It can also mean that if a machine operator is absent, another trained employee is there ready to step in. Having a pool of backup staff and flexible shift arrangements helps ensure your production never stops, even when faced with dire situations.

Routinely review and adjust work schedules:

You need to keep a close eye on your shift patterns to make sure they're actually working, and pay attention if your people are getting too worn out. Nobody wins when workers are exhausted.

So, if it seems that the current shift patterns are not working, just tweak the schedules when needed to keep both the business running smoothly and your team happy. With robust shift management software, it won’t be a hassle since you can overview the patterns easily and by customized views and make quick adjustments.

The Bottom Line

Manufacturing, just like any other sector, needs people to get the work done. When employees are great at their work, production is at its peak, and when they are underperforming, production suffers. The way you schedule shifts can make or break your team's performance.

This comprehensive guide on optimizing shift schedules in manufacturing should help you understand and address several key challenges in the process – from pinpointing what's causing your current shift issues to determining which shift pattern would work better, how to optimize scheduling with shift management software, and more.

We're excited to hear how helpful this blog has been for you. Share your feedback and concerns in the comments.

If you're looking to switch to a more powerful and tailored shift management software for your manufacturing operations, Mewurk is the best choice you can think of right now. We let you try our demo free of charge for up to a year so you can decide if it's really worth the investment. Contact us for more details.