Case Study 3-05498
IET’s client needed the ability to adjust their costs on a weekly basis due to varied customer demands, a challenge of their industry. IET provided a direct and indirect labor plan that would allow a 35% flex up and down from average weekly demand, while ensuring that the skilled labor pool was motivated to support these adjustments.
Sunrise Windows, an award-winning designer and manufacturer of custom vinyl replacement windows for residential markets.
IET first streamlined the production processes to increase overall labor productivity and reduce production throughput time to one-day. These changes also enhanced workplace organization and the shop floor’s appearance, which played a role in improving morale. The next step involved creating a staffing plan that
Using a core operator group who possessed the necessary knowledge and skills as a starting point, Sunrise and IET developed a flexible work schedule based on two 10-hour shifts, Monday through Thursday. By working Friday, the company could accommodate a 25% increase without adding people. Volume increases beyond this level would be staffed with temporary workers who perform non-critical production and support operations. Routine weekend shifts that contributed significantly to operator “burn-out” were eliminated. Weekly labor requirements were calculated based on product mix and volume and summarized in a Manning Chart that indicated the required number of operators and hours per week. Workforce planning was simplified. Labor costs were brought under greater control. Operator morale improved. Everybody won!