Implementing Best Practices in Multishift Operations

Implementing Best Practices in Multishift Operations

OBJECTIVES

• Learn proven Best Practices in 24-hour management
• Apply World-Class Manufacturing (WCM) strategies in a multishift environment
• Create seamless intershift communications
• Improve process reliability and plant capacity utilization
• Explore alternative shift schedules that reduce costs and improve job satisfaction
• Develop the 5 Cs (Communication, Coordination, Continuity, Consistency & Commitment) across all shifts
• Implement Kaizen (continuous improvement) around-the-clock
• Learn what has worked – and what hasn’t – at other plants
• Develop “value-added” leaders plant-wide
• Benchmark your performance against that of world-class facilities
• Create an Action Plan for continuous improvement back at work
• Achieve bottom-line results within 6 months

WHO SHOULD ATTEND?

Plant/operations professionals, shift supervisors and professionals from HR, Quality, Maintenance, Engineering, Training & Development, Logistics & Customer Service will receive excellent value.

COURSE OUTLINE

Day One

Building a Competitive Advantage

• The 5 Cs of 24-hour management
• Benchmarking world-class operations
• Performance results from successful plants
• Self-Assessment – How does your plant measure up?

Best Practices in Capacity Utilisation and Process Reliability

• Measure true asset utilisation
• The 6 manufacturing losses
• World-class Maintenance in a 24-hour operation
• Improving Overall Equipment Effectiveness (OEE)
• Strategies for achieving Zero Defects
• Strategies for building in quality at the operator level
• Establish standardised procedures across all shifts

Day Two

Best Practices in Plant Communications

• Deliver effective management communication to all shifts
• Improve shift leader-team communications
• Develop effective interfaces across shifts
• Proven cross-shift communication tools & techniques
• Install a world-class Visual Management system

Day Three

Best Practices in 24-Hour Leadership and Employee Involvement

• Ensure round-the-clock involvement of all associates
• Build and maintain a positive, results-oriented work environment on all shifts
• How to successfully implement cross-shift teams
• Management’s role in leading multishift operations
• Develop “high-performance” first-line leaders on the plant floor

Day Four

Management Support for 24-Hour Operations

• Continuous improvement systems that involve all shifts
• Training strategies in a 24-hour operation
• Staffing strategy to support world-class operations
• Essential support requirements for the late shifts

Day Five

Best Practices in Plant/Work Force Scheduling

• Review of key scientific studies on shift work, health and alertness
• Managing the risks of shift work
• Common shift scheduling myths
• Strategies to enhance employee alertness on shift
• Determine the cost-effectiveness of your shift schedule
• Examples of 8-, 10- and 12-hour schedules
• Fixed vs. rotating shifts
• Step-by-step process to design and implement a “lean” shift schedule
• Analysis of delegates’ shift schedules and issues

Applying the Learnings

• Group Vision and Action Plan