How Two Foundries Got Stuck in a Cycle of Burnout and Loss
Circadian Case Study: Ductile and Gray Iron Foundries - Automotive Applications Solution Twelve-hour Shifts Improve Attendance and Performance
Two sister foundries in the Midwest were trapped in a damaging cycle of excessive turnover, absenteeism, and rising injuries, primarily caused by a fixed 3-crew, 8-hour schedule without routine days off.
This outdated system, initially designed for a 5-day operation, couldn’t keep pace with their continuous operations. The foundries relied heavily on an overtime policy that paid time and a half on Saturdays and double on Sundays, which locked employees into exhausting 50-70 hour workweeks.
Extreme summer conditions only worsened the situation, leading to spikes in absenteeism and turnover as both management and workers became stuck in "golden handcuffs." Discover how these foundries addressed the root of their issues and sought a path to recovery.
