A busy chicken factory processing an average of one million birds per week became a major supplier to a leading UK supermarket. Five times per year a substantial product promotion created a sudden surge in demand, which required additional Saturday shifts at short notice.
With packers, engineers, warehouse and dispatch staff plus administrators all required for these additional ad-hoc shifts, the factory struggled to meet demand at relatively short notice.
Supply Chain Precision consultants worked closely with the company from the ground up to implement a highly incentivised rolling Saturday shift pool, whereby staff from all required departments were encouraged to log their availability for weekend work over the next four weeks.
As the system rolled on, senior management could always see available ad-hoc staffing levels for the coming month.
Staff who worked additional Saturdays benefited from three times their usual hourly pay and were given meat to take home. The planning of heavy production demand periods became easier and more strategic and there was a visible improvement in actual OTIF supply of orders to one of the UK’s leading supermarkets.