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20% more production at Kankakee, with union support
Sun Chemical
Chemical & Process
+20%
more production captured at Kankakee
90 of 120
hrs effectively run before
3-day
planned breaks
The problem
Pandemic-era demand and workforce changes pushed two plants into a year of high overtime and regular Saturdays, and they still fell behind. Franklin was staffed for 120 hours a week but effectively ran about 90. Kankakee regularly ran 6 days with understaffed, low-tenure back shifts. Employees were tired and burned out.
What we did
- Surveyed employees and presented multiple options to meet time-off and productivity goals
- Supported Kankakee's newly elected union leaders on-site during first-contract negotiations
- Implemented an interlocking 8 and 12-hour schedule at Franklin
- Applied a Best Equipment Strategy at Kankakee, running the most efficient equipment for the most hours
- Revisited training, vacation, and supervisor alignment policies
The results
- +20% production captured at Kankakee, with union support
- 5 days: Franklin returned to a five-day week
- Regular three-day breaks and fewer weekend days for employees
- Voluntary overtime and predictable shifts that attract new talent
Running Saturdays and still behind? Get a 30-minute workforce diagnostic.
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