Seven Ways to Spur “Peak Season” Production

For most manufacturing companies, the year is filled with peaks and valleys. Although the busy season is more profitable, it brings with it an unusual set of problems. The most critical aspect is to keep production moving forward at a rapid clip with minimum disruption. A high incidence of employee absenteeism or tardiness may have a domino effect on the operation.

The following are seven ways to provide some protection during the busiest times of the year.

1. Offer extra incentives to employees for achieving perfect attendance. This might take the form of rewards for perfect attendance (e.g., gift certificates for restaurants or the local electronics outlet). Similarly, the company can hold a raffle for staffers who have not missed any days or shown up late.
2. Conduct cross-training sessions. It is a good idea to teach employees how to do more than one job. This not only provides greater coverage on the plant floor, but it may also motivate workers who otherwise feel “stuck in a rut.” It is often surprising how many employees will rise to the challenge.
3. Outsource low-tech jobs. A temporary agency—and several other agencies—can provide enough workers needed to survive the peak season. Outsourcing can be particularly effective when it is combined with cross-training. For example, workers normally on the receiving line can move to production while temps pick up the receiving slack.
4. When necessary, authorize overtime. Obviously, excessive overtime can erode the bottom line. But it may be a viable solution on a selective basis. (Workers will generally welcome the opportunity to earn extra income.) Note: Overtime may be less costly than outsourcing when training expenses are factored into the equation.
5. Seek extra workers to fill in the gaps. If more manpower is needed on the floor, business associates and employees may be good referral sources. Traditionally, some manufacturing companies shy away from hiring friends and relatives, but this might be a viable temporary solution.
6. Go to the head of the class. Consider tapping into the student body at a local college or university. Frequently, the availability of students will coincide with the shifts that are undermanned. Depending on the type of operation, it may even be worthwhile to use technologically savvy students in a supervisory capacity.
7. Be creative. Do not simply adhere to the practices followed in previous years, especially if problems were encountered. Try to think “outside the box.” Brainstorm with other managers of the company and business advisers.

It is especially important to address these issues beforehand. Once the peak season has arrived, it may be too late to implement strategies.

April 2008