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More than 90% of employees voted to go back to the 12-hour, 7-day schedule

More than 90% of employees voted to go back to the 12-hour, 7-day schedule

Dal-Tile

Manufacturing

90%+

of hourly team members chose to return to the 7-day, 12-hour schedule

0 to 24/7

in 12 months

5-day

breaks without vacation

The problem

Dal-Tile was building a greenfield plant in Dickson, TN and wanted it to run well from day one. Leadership needed a schedule that would let them hire, train, and keep a new workforce, balance skills, and cross-train during the first 18 months, all while ramping from early training to full 7-day, around-the-clock production in 12 months. The management team was new to the area and its customary schedules.

What we did

  • Surveyed surrounding businesses and drew on CCG's schedule database to predict what future employees would want
  • Designed ramp-up schedules using 8 and 12-hour shifts, from start-up in summer 2015 to continuous 7-day operations
  • Built a 12-hour, every-other-weekend-off rotation with some five-day breaks
  • Set policies such as a slightly shorter night shift, balanced week-to-week pay, and counter-rotating supervisors

The results

  • More than 90% of hourly team members chose to return to the 7-day, 12-hour schedule after a temporary move to Monday to Friday
  • 12 months from early training to full 7-day production
  • Five-day breaks without using vacation time
  • Reduced costs and higher margins after returning to 7-day production in fall 2018
When Coleman Consulting Group started this process in 2014, they exposed me to so many ideas and schedule concepts that I didn't know existed. Our entire team here at Dickson have benefitted tremendously from the work we did with Coleman.

Brent Shoemaker, Director of Manufacturing, Dal-Tile

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