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55% fewer call-offs and 10% more beer

55% fewer call-offs and 10% more beer

Molson Coors

Food & Beverage

-55%

employee call-offs

+10%

beer produced

80%+

stayed on new schedule

The problem

New craft lines pushed the Milwaukee Brewery's summer peaks to 24x7 demand. Overtime grew beyond what employees wanted, and Wisconsin labor laws and union seniority rules made hours less flexible and predictable. The result was higher costs, more absenteeism, low morale, and costly production misses.

What we did

  • Analyzed workload, workforce, absenteeism, turnover, logistics, sales, and returns
  • Surveyed the workforce and benchmarked against CCG's employee database
  • Educated union leadership and site managers through a series of meetings
  • Designed an unbalanced 7-day schedule, adopted by employee vote

The results

  • 55% reduction in employee call-offs
  • 10% more beer than the prior year, with fewer production misses
  • 80%+ of employees chose to remain on the new schedule after one year
  • Huge reduction in weekend forced overtime
They worked directly with our employees and union leaders to go from an environment of skepticism to an employee vote that changed the brewing schedule dramatically. This new schedule helped our business create more capacity, but most importantly drove improved morale as a direct result of the new schedule.

Ken Litke, VP Manufacturing, Molson Coors

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