Struggling with a 2-Day Week-Off Plan in Manufacturing: How Can We Make It Work?

Implementing a 2-Day Week-Off Plan in Manufacturing

My company is planning to implement a 2-day week-off plan, and we are having difficulty making it a success in the manufacturing division for our staff. I have been working on this and have a solution, but it is not complete. I would like to ask for your help with the same.

Current Scenario

The company is involved in manufacturing construction chemicals, covering an area of 100,000 square meters with 6 plants, 110 workers, operators, engineers (7), and a production manager.

All the engineers are trained to handle all the stations, but one engineer has to always be on the day shift as he looks after the ERP systems.

So now, leaving the manager aside and the ERP guy, we have 5 engineers who have to come in a rotational shift (3 shifts) and look after 6 plants. We need it to be done for 5 days.

Proposed Plan

I have planned in such a way that engineers will work on all the days, taking their 2 days week off without any extra cost, by following the roster system.

I need your help to modify my schedule and guide me accordingly. Your immediate response will be highly appreciated.

Thank you,

Regards,
Mr. Amrut

To successfully implement a 5-day rotational shift schedule for the manufacturing division staff, consider the following steps:

1. Assess Current Workload and Shift Requirements:
- Evaluate the workload distribution across the 6 plants and determine the optimal number of engineers needed per shift to ensure smooth operations.

2. Design a Rotational Shift Schedule:
- Create a rotational shift schedule that accommodates the 5 engineers across the 3 shifts for 5 days a week. Ensure that each engineer gets 2 days off without incurring extra costs.

3. Consider Skill Requirements and Specializations:
- Assign engineers to stations based on their skills and expertise, ensuring that the engineer responsible for ERP systems is available during the day shift.

4. Implement a Roster System:
- Develop a detailed roster system that clearly outlines the shift timings, plant assignments, and off-days for each engineer. This system should be transparent and easy to follow.

5. Monitor and Adjust:
- Regularly monitor the effectiveness of the new schedule and gather feedback from the staff. Make adjustments as needed to optimize productivity and employee satisfaction.

By following these steps and maintaining open communication with the staff, you can successfully implement a 5-day rotational shift schedule that meets the operational needs of the manufacturing division.