Best Practices in Multi Shift Operations

This intensive course will highlight how the world’s most successful companies manage multiple-shift and 24-hour operations to deliver world-class people and process performance.

All industries are highly competitive so in order to compete successfully, 24-hour operations must continuously improve to achieve the highest possible standards at all times.

For a facility to operate safely and efficiently 24/7, it is important to apply shift working best practices. Multiple-shift operation poses a challenge because of the potential for fatigue and disconnects caused by the fact that the personnel are changing every few hours.

This can result in a significantly increased risk of incidents and operational problems such as reduced throughput, poor communication and increased levels of waste.

Objectives

• Recognize and appreciate the issues associated with 24/7 shift operation.
• Identify strategies to deal with the issues.
• Benchmark your performance against that of world-class facilities & explore alternative shift schedules.
• Build up effective Shift Supervisors.
• Create an Action Plan for continuous improvement back at work.

Course Outline

Day 1

Comprehending the issues associated with shift working

• Shift Working Self-Assessment – How does your operation measure up?
• Communication.
• Continuity of operation and Consistency of approach.
• Benchmarking against world-class operations.
• Shift-to-shift handover.
• Fatigue and its consequences and other People issues.
• Sharing the specific issues of the course delegates
• Case Studies

Day 2

Effective Communications, Effective Shift Handover & Continuity of Operation

• Deliver effective management communication to all shifts.
• Improve shift leader-team communications.
• Develop effective interfaces across shifts.
• Best practices for effective shift handover and Start of shift meetings.
• Teamwork.
• Effective standard operating procedures.
• Training and developing Shift Teams.
• Case Studies

Day 3

Developing Effective Shift Supervisors, Continuous Improvement/Kaizen in 24-Hour Operations

• Evolution of the role of supervisor.
• Training and developing effective supervisors .
• Benchmarking performance of supervisors.
• Understanding CI.
• Workplace organization, 5S and TPS.
• Management visibility/GEMBA.
• Case Studies

Day 4

Dealing with Fatigue, Pros and Cons of Different Shift Systems

• The body clock and circadian rhythms.
• Causes of fatigue & Fatigue Countermeasures.
• Ergonomics.
• History of shift working.
• Alternative Shift Schedules.
• Analysis of delegates’ shift schedules and issues.
• Case Studies

Day 5

Dealing with People Issues on Shift

• Managing performance.
• Dealing with poor performance.
• Improving Motivation and Counselling.
• Discipline.
• Consistency of approach.
• Applying the Learning – Group Vision and Action Plan
• Case Studies