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New-hire turnover above 50%, brought down to manageable levels

New-hire turnover above 50%, brought down to manageable levels

Therma-Tru Doors

Manufacturing

50%+

new-hire turnover, brought down to manageable levels

0

shift overlaps

4x10

schedule option

The problem

COVID-era demand and supply chain delays forced constant overtime at Therma-Tru's Indiana distribution centers. 8-hour shifts stretched to 10, most Saturdays were worked, and volumes swung so workers were either idle or overwhelmed. Tenured employees quit, and new-hire turnover topped 50%.

What we did

  • Used management interviews, observation, and real-time data to find overlaps, aisle congestion, equipment shortages, and idle time
  • Surveyed employees on what mattered most
  • Moved shifts to an earlier start to put more people on site at peak times
  • Added a 4-day, 10-hour option for more consecutive days off

The results

  • 50%+ new-hire turnover reduced to manageable levels
  • Eliminated shift overlaps and reduced idle time
  • More coverage for live loads
  • Overtime available by choice instead of forced

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