Introduction

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 Outlines:

Day 1

Methodology of Multi-Shift Operations and Recognising the Problems

• Measuring the work operation and self-assessment
• How to communicate efficiently?
• Consistency in approach
• Handing over of shift and change of shifts
• Recognising the world benchmark in multi-shift operations and trying to adapt

Day 2

Case Studies on Efficient Handing Over and Shift Change and Continuity of Operations

• How to effectively communicate and manage all shifts?
• Communications with shift leader
• Teamwork and effective operation procedures
• Training on shift teams

Day 3

Effective Shift Supervisors and 24 Hour Operations

• Understanding the role of the supervisor
• Training of the shift supervisor
• Concept of “Continuous Improvement”
• Concept of “Kaizen” and implementation TPS methodology and 5S methodology
• Understanding the methodology of “GEMBA” – a Japanese term meaning “the actual place”

Day 4

Understanding the Advantages and Disadvantages of Multi-Shift Operations

• Effect of fatigue and injuries in multi-shift operations
• Scheduling of alternate shifts
• Analysing delegate shift schedules
• Understanding the body clock and circadian rhythms and its importance in shift management

Day 5

Understanding and Dealing with the Issues of People in Multi-Shift Management

• How to deal with poor performance?
• Motivation and counselling
• Importance of discipline in shift operations
• Consistent approach
• How to manage and analyse performance and provide efficient reviews
• Case studies on Action plan and multi-shift operations in biggest companies
• Review of the course and “Question and Answer session”