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MAPP Plastics Discussion Forum

The MAPP Plastic Industry Discussion Forum allows members to rapidly communicate with each other. Post both questions and answers to questions that other MAPP members have about any industry topic from material and process issues to R&E Tax Credits and other business issues.

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Posted:  07 Jul 2016 23:16
Does anyone have suggestions for and experience with a 24/7 four (4) shift schedule for an injection molding facility? We are looking at options for the future and would like to hear from folks who've made the switch.

Ed Chappel
Posted:  08 Jul 2016 14:00
We made this transition from 5 days a week, 3 shifts, 8 hours) about 7 years ago (because we were running almost every weekend anyway and people were being crushed by the overtime).

PRO:
*  Most everybody likes the fact that they get 15 days off a month.  This is a big benefit for folks.  Even though they were terrified by it at first, after the change was made we had zero complaints.
*  Minimized OT, and reduced overall labor costs.

CONS
*  For older associates, 12 hours on a concrete floor is a long time and they are tired.  It is a long day.
*  It is more difficult to commmunicate and get everyone on the same page (because you have 2 day shifts and 2 night shifts).  Supervision needs to truly work like management - coming in on their off days for training and communication.
Posted:  08 Jul 2016 14:28
Ed, this is a topic that has been discussed much over the past couple of years.  In fact, if you logon and go to the Forum area where you posted this, you can use the Search feature to find every posting with the word "shift." 

One post, from Eric Paules of Crescent Industries talked about their adoption of a blended schedule that worked very successfully.  He sited a website: http://shift-work.com/.

Others that I can link you with would be the lead executives of PRD, Thogus, Metro and others.

Let me know who you want to speak with, and I will make the introductions for you!

Thanks!

Troy Nix
Posted:  08 Jul 2016 15:14
Ed,

We have been running a 4 shift 24/7 schedule for 15+ years. Here is an outline of our schedule.
•       Team A: Sunday – Tuesday; 7 am – 7 pm
•       Team B: Sunday – Tuesday; 7 pm – 7 am
•       Team C: Wednesday – Friday; 7 am – 7 pm
•       Team D: Wednesday – Friday; 7 pm – 7 am
•       Team A/B and C/D rotate Saturdays.
Thus each team works 36 hours one week and 48 hours the next week for an average pay of 44 hours.

It has worked great for us and we would highly recommend it. The biggest issue is to update your policies to be flexible with all the different shifts/times and also to provide support coverage 24/7 (maintenance, engineering, etc.).

If you have any questions, or would like to discuss in more detail, please let me know.

Best Regards,
Team 1 Plastics, Inc.
Craig Carrel
President

Phone #: (517) 629-2178 ext. 211


Troy Nix
Posted:  14 Jul 2016 17:11
Ed:  Ironwood went to the following schedule. 
Weekend shift works 2 12 hours shifts
Day shift is Saturday and Sunday 7 am to 7 pm
Night shift is Saturday and Sunday 7 pm to 7 am

They also put in one 8 hour day during the week.  This allow us to have workers during the week as well. 

they work 32 hours, but we pay a high enough shift premium that it is like working 40 hours.

Theresa Turlua
© 2014 Manufacturers Association of Plastics Processors