There are many aspects to the concept of Lean Manufacturing and Lean Thinking. One of the fundamental goals of applying lean concepts is to eliminate waste in the process.
What can we do to minimize waste in shift schedules? In no specific order, here are some places to look:
- Match the coverage to the workload
- A headcount mismatch creates idle time, overtime, and lost capacity (if you are unable to run)
- Avoid overstaffing to cover absences.
- Create time for preventative maintenance
- Make your product right the first time – avoid defects and extra processing resulting from machines that are out of adjustment.
- Avoid waiting due to breakdowns.
- Reduce operating costs due to improved equipment efficiency.
- Allow shift workers to get rest (days off, hours/day)
- Reduce defects due to human error.
- Feel better, better performance, clearer thinking, and more interest in engagement.
- Less pacing due to fatigue.
- Smooth production and create flow using a continuous schedule (24×7)
- Reduce finished goods and work-in-process inventory.
- Match production to demand.
- Find defects when they occur and correct the cause immediately.
- Maximize asset utilization.
- One potential risk is the increase in overhead staff because of an increase in the number of supervisors and indirect support personnel.
- Operate through breaks and lunches
- Avoid line instability that results in defects and line startup/shutdown costs.
- Maximize capacity and asset utilization.
- Insufficient cross-training
- Waiting to get the right person for the job
- Not utilizing the potential for on-shift personnel to fill more roles
I’m sure you can come up with more opportunities to add to my list.
Improving your schedule by addressing sources of waste requires making changes. Changing schedules is not easy, but it can be done. Our change process engages the workforce in the schedule evaluation and incorporates their feedback into the best solutions that result in a leaner, more efficient, and productive operation.