Shift planning for optimal efficiency
July 2010
IT in Manufacturing
ApplyIT enhances operations planning with OpSUITE electronic shift roster.
ApplyIT has eased site operations planning for plant managers, foremen, superintendents and team leaders with the integration of electronic shift roster (ESR) functionality into OpSUITE, its already comprehensive operations suite. OpSUITE ESR is an optimised electronic solution specifically designed to improve the process of planning and controlling shift patterns on site.
Planning and managing shift cover for continuous operations is a basic requirement on most sites. Traditionally, the process is handled manually using spreadsheets, a cumbersome approach that becomes increasingly complex over time, with the information eventually becoming the responsibility of just a few individuals.
The complexities of a spreadsheet shift roster system are numerous, making the system inadequate for effective site operations. Establishing suitable shift patterns to meet the demands of the particular organisation is one thing; applying the roster to specific roles and gracefully handling the inevitable changes to the plans of a large site is a problem of an altogether different order. Shift changes need to be communicated clearly to all affected personnel. Planning conflicts like double shifts and mismatched skills need to be resolved timeously and accurately, so as not to interrupt processes or disrupt plant efficiency. OpSUITE ESR handles a wide range of shift patterns based on shift durations, the number of teams and the length of shift cycles. Through the system, individuals are assigned to shift teams and fulfil specific roles depending on their skills and training.
Shift plans can be easily reviewed by the employees involved and the shift planner. Any changes necessary are immediately visible and the system outputs a personal calendar for each employee. The system provides the necessary checks to ensure that any resource conflicts are identified and can be resolved.
ApplyIT product development manager Scott Bredin says that what makes OpSUITE ESR different from other types of electronic shift roster systems is that the system is linked to an employee’s competencies. “Every role on a plant requires specific competencies. For example, a boiler operator requires a specific set of skills before he is allocated a controlling role, or issuing permits to work for maintenance crews in that section of the plant. OpSUITE ESR checks the person’s training record and their level of authorisation to make sure that the individual is fully equipped before being booked onto that shift. This ensures that every person allocated to a shift is suitably qualified for the tasks they will need to perform,” he says. “The application improves coverage for shift positions, provides a fallback to alternative rosters for situations where a position is short-staffed, and records who was on which shift and at what time.”
OpSUITE, of which the ESR module forms a part, is designed for asset-intensive companies that operate hazardous processes. The technology includes a range of solutions for site safety, plant and equipment management, environment, health, quality and sustainability, compliance and operations performance. The ESR module can also be run as a standalone system and still yield all the benefits of consistent and accurate shift rosters.
For more information contact Scott Bredin, ApplyIT, +27 (0)31 275 8083, [email protected], www.applyit.com
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