The introduction of a new shift pattern is always fraught with difficulty. People get used to and build their life around a shift pattern. The level of investment in a Dairy or Pharmaceutical Plant dictates a 24 hour working pattern. In some cases cleaning especially CIP can be done at unsocial hours and usually product set up or changes are completed during the day when there is a management presence on site.

A new plant has a chance to introduce a sensible roster pattern from the first day. Most existing plants have bespoke shift patterns which hark back in time and possibly involve substantial overtime premiums being paid to a small number of people who are willing to work all hours if required to do so. The objective is to match the plant requirement with the resources at the optimum time. With extensive consultation and common sense it is possible to introduce a new pattern into an existing operation. We have done so many times with major increases in productivity.  

The rotating four days on four days off 12 hour shift 07.00-19.00 and 19.00 to 07.00 with people always on days or nights has proved to be very effective. We have found a rotating 12 hour day and night four on, three off to be effective in traditional plants where the shifts have always shared the unsocial hours. Over time the Plant Operators changed the pattern to maximize their time off and the shift pattern became similar to the DuPont one. 

DuPont 12-Hour rotating shift example:

1 Nights Nights Nights Nights Off Off Off
2 Days Days Days Off Nights Nights Nights
3 Off Off Off Days Days Days Days
4 Off Off Off Off Off Off Off

In the Hospitality sector split shifts are common, and we have had to create many bespoke shift patterns in the Retail Sector. The balancing exercise in the Retail Sector is to match your best people with the Peak selling times over a seven day week. Flexibility is the key with a mix of full time and part time resources.

We would be happy to discuss or design an appropriate shift pattern for you!