Best Practices in Multishift Operations

Courses Syllabus

Introduction

This course will reveal 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 necessary 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.

This course will feature:

• Why 24/7 operation needs multiple-shift working
• How Shift working introduces extra challenges
• Communication and leadership for shift working
• Why shift working increases risk from fatigue and at changeover
• Development of strategies to manage shift risks & issues & become a world-class 24/7 operation

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.
• Develop effective Shift Supervisors.
• Create an Action Plan for continuous improvement back at work.

Content

Day One

Understanding 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 Two

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 Three

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 Four

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 Five

Dealing with People Issues on Shift

• Managing performance
• Dealing with poor performance
• Improving Motivation and Counseling
• Discipline
• Consistency of approach

Applying the Learning – Group Vision and Action Plan

Case Studies