Shift Work Blog

Often, when we start on a project with a company, the question will be asked, “Can we put in more than one schedule?” The intent is to discern if such a thing is actually possible or too complicated to consider.

The answer is almost always, “Yes, in fact you already have multiple schedules being worked at this site.”

It would be a rare find indeed if a company was operating with its entire workforce on a single schedule. It would be even rarer if such a singular scheduling scenario was optimal from an efficiency perspective.

Consider your basic operation where there is a maintenance crew and a production crew. Quite often, these two disparate operations are on the same schedule in spite of the fact that one cannot do its job while the other is working. You can’t run a line that is taken apart for maintenance and you can fix a conveyor belt that is moving.

So different schedules are not only possible, but often necessary for the efficient operation of the facility.

Suppose that you have two different schedules but they are both in maintenance or both in production. It that feasible?

Certainly. If you have, for example, three identical production lines and you can only meet production demands if one of the lines is running 24/7, then it make sense to have one line run 24/7 while the others remain on a 5-day schedule.

While this is efficient, it can lead to complications when it comes to issues like overtime, absentee coverage and seniority. For example, if a 12-hour, 7-day schedule and an 8-hour, 5-day schedule both start at the same time and there is an absence on the 12-hour schedule, what do you do? Do you cover it by calling in a 12-hour person on their day off? Do you hold over an 8-hour person that is expecting to go home? If both options are available, who chooses which option will be used? Suppose there is a 12-hour person at home that wants to come in for the overtime but there is a more senior 8-hour person that wants to hold over; does seniority rule or does the person on the schedule get priority?

Suppose a person on a 12-hour schedule wants to take 2 weeks of vacation and an 8-hour person steps into the 12-hour schedule to fill the position, are there any policies that will be impacted? This seems like a simple issue until you understand that often pay and work policies for an 8-hour schedule do not work well for a 12-hour schedule.

The list of considerations goes on and on. Suppose there is a layoff on one product line on one schedule but not on another product line on a different schedule? If you lay off by seniority and a senior person stays but has to change lines and schedules and then wants to take vacation, will your policies work?

If you have one supervisor covering two lines and the lines are on different schedules, what schedule will the supervisor work? The more time he spends one one schedule with one crew, the less time he will spend with the crew on the different schedule.

Finally, different schedules have different levels of attraction. Are you willing to allow skilled employees to migrate to the more attractive schedule?

Multiple schedules not only work, they are often more beneficial to the company. However, be prepared for the complications that can arise from such a shift work structure.

Most people that come to our site are thinking “I need a shift schedule so all I need to do is search the internet until I find a pattern that I like.”

There are several “Danger Will Robinson” issues associated with this idea. First of all, what you like may not be what everyone else likes. Secondly, what everyone else likes may not be what is best for your company.

Suppose you like to work the Day Shift and have all of your weekends off. It won’t be hard to find a schedule that provides this type of pattern. Now, suppose you work at a refinery that runs 24/7. If you have all day shifts, then others are having to work more non-day shifts. If you have all of your weekends off, then others will have to work the weekends more often. So you can see, satisfying your personal preference may not satisfy the preference of others.

Take this same refinery. Suppose everyone agrees that weekends off would be a good thing. You will have no problem finding a schedule that gives all of the weekends off and you will certainly have no problem getting a consensus that such a schedule is a good idea from a lifestyle point of view. However, a refinery must run on the weekends. Having a schedule that gives everyone the weekends off will not change that fact.

Here are a few ways that schedules differ:
amount of coverage
amount of overtime
scheduling maintenance
scheduling vacations
absentee coverage
product flow
health and alertness
shift length
number of days in a row
fixed or rotating shifts
fixed or rotating days
cross training
sanitizing schedule
shipping schedule
warehouse capacity and scheduling
seasonality
discretionary work
overtime pay and policies

This list can go on and on. Different companies, even within the same industry often need different schedules.

Take the time to do the research and find out what you should be thinking about for your situation. We are here to help. Call our office to discuss your situation with one of our shift work experts. There is no charge for the call so if you have a question, there is no reason not to ask for help.

I recently received a telephone call from a company that was having problems with their shift schedule.  The problem, it seemed, was that people were complaining about the schedule.  The company could hear the complaints but was having a hard time interpreting what they were hearing.  Was it just a few “squeaky wheels” doing all of the complaining or was their a general rumbling throughout?  Was there a specific problem or were there several issues?

The obvious concern the company had was that they needed to qualify and quantify the problem before they could take action to fix it.

This is where we came in.  Our two-survey process accomplishes the following:

The entire workforce is involved.

One person, one survey eliminates the “squeaky wheel” issue.

The first survey finds the problem, the second survey narrows down the possible solutions

The surveys made sure everyone knows what is going on.

The results from the surveys are shared with the workforce making the process “transparent” and the results data-driven.

If you are planning a change to your shift schedule, regardless of how small and apparently inconsequential, get the workforce involved.  It is their schedule.  They have structured their lifestyles around it.  Any change will have an impact on them and their families.  Getting them involved helps them to understand what is happening, why it is happening and when it is happening.  It also lets them have some input into the final solution.