Shift Work in a Manufacturing Environment

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Shift Work in a ManufacturingEnvironment

• Dagenham

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Dagenham Manufacturing Plant

• Engine Plant
• Year Opened 1931
• Current Total Employment2,047   
• Hourly 1,895      Salaried 152
• Current Products 1.8L TDCi, 2.0L TDCi, 2.4L
  TDCi, 2.7L V6 Diesel, 3.6L V8 Diesel, 2.2 litre
  TDCi

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Why do we have Shifts

• To maximise production
• Fixed costs are there regardless, so why not use
  them.
• To get maximum use from the Machinery
• Through maximising the work force and facilities,
  Dagenham is on target to produce 1 million
  engines this year

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Shift Patterns

• There are 3 shift patterns
• Day Shift
• 2 shift alternating earlies and lates
• 3 Shift - Alternating lates, earlies, and nights
• Maintenance
• Set number of hours in a month 12 hour shift
• Totalling around 148 hours a month.
• Vacation
• Shut down 3 weeks in summer and Christmas

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Key challenges

• Casual Absence - leads to problems manning the
  lines
• Boredom due to repetition, can lead to absence.
• Motivation of Money every one wants to work on
  a 3 shift area
• Tiredness Very physical work combined with
  changing timing of working.
• Health Issues- people can be susceptive to
  repetitive strain, or musco skeletal problems

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Solutions

• Casual Absence tackled by the overtime ruling
• Factoring in man power for absence cover.is 10
• Boredom - recruitment screening processes ask
  individuals how they cope with repetitive tasks
• Learning resource centre for job related
  training.
• Pairing up scheme -learn others jobs in order to
  move people around.
• Dedicated and well trained team leaders not
  working on line but there to motivate team and
  monitor quality.
• Design of Shift patterns.
• Tiredness
• - Regular Breaks with quiet seating areas
• Canteen facilities are operate through all shifts
  so night shift is catered for
• No Weekend working

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Any Questions