The 4-Day Work Week in Manufacturing (2024)

According to a report, the burnout rate in the manufacturing industry stands at 77.4%. This alarming figure likely arises from tight schedules and high workloads.

As companies strive to boost productivity and employee satisfaction, a 4-day work week has gained popularity. But is it feasible for the fast-paced and demanding manufacturing environment?

Today, we'll examine the potential benefits and challenges of adopting a 4-day work week in this critical sector. Let's explore whether it could lead to a more balanced, efficient, and satisfied workforce.

Overview

In the manufacturing industry, where employees create physical products that typically require a fixed amount of time, the feasibility of adopting a four-day workweek remains uncertain.

Several companies, especially in Europe, are testing compressed schedules to see if reduced hours align with the high-energy demands and continuous operations of manufacturing. The prime examples include 5 Squirrels Ltd and Lamborghini.

Companies are experimenting with various approaches: some extend daily hours over four days, while others maintain standard shifts but enhance operational efficiencies to provide an extra day off.

Typical Working Schedules in Manufacturing

The traditional manufacturing work schedule typically operates on a standard five-day, 40-hour workweek, with shifts commonly structured around the clock.

This model includes first, second, and third shifts to maintain continuous production 24/7.

The first shift usually runs from early morning to mid-afternoon, whereas the second shift covers the afternoon to late evening. The final shift, often called the graveyard shift, operates throughout the night until early morning.

Benefits of the 4-Day Week Model for Manufacturers

The four-day workweek model can offer numerous benefits for manufacturers, including:

• Increased employee retention: Manufacturers often face high employee turnover due to the demanding nature of the work. A 4-day work week could give employees a better work-life balance, leading to higher retention rates.
• Reduced operational costs: Operating a factory or plant for one fewer day each week can lead to substantial savings in energy costs and other operational expenses such as heating, cooling, and maintenance. These savings can be significant, especially in energy-intensive manufacturing processes.
• Talent attraction: As the job market evolves, more workers prioritise flexibility and work-life balance. Manufacturers offering a four-day workweek can attract more applicants who value the extra day off.
• Increased productivity: One of the primary benefits of a four-day workweek is the potential increase in productivity. Despite working fewer hours, employees tend to maximize their output during their active hours, which can lead to more efficient production processes.

Challenges of Adopting a 4-Day WorkWeek

While the 4-day workweek holds promise for many industries, manufacturers may face unique challenges when considering this shift.

Let's look closer at sLet'sf the major hurdles:

• Production slowdowns: Manufacturing often involves physical processes that take a set time to complete. Reducing work hours by a day can lead to production slowdowns and missed deadlines if not addressed strategically.
• Labour shortages: The manufacturing sector already faces a shortage of skilled labour, and reducing work hours might further strain available resources, making it harder to maintain production levels.
• Supply chain disruption: A shorter workweek can complicate coordination with suppliers and logistics partners who operate on traditional schedules. Adjusting delivery and pickup schedules to fit a 4-day format without causing delays requires robust communication and possibly renegotiating contracts and agreements.
• Shift coverage complexity: Manufacturing relies on multiple shifts to keep production running continuously, and a four-day workweek could complicate shift coverage, especially if employees are unwilling to work weekends.
• Increased operational costs: To meet production demands, companies might need to pay more overtime or hire additional temporary or part-time workers, which could offset the benefits of a shorter workweek.

Case Studies of Successful Implementations

Let’s have a look at suLet'sful 4 day work week implementations in the manufacturing industry:

1. CMG Technologies

CMG Technologies, a UK-based manufacturer specializing in 3D metal printing and metal injection moulding, adopted a 4-day workweek in 2015. This shift was implemented to enhance work-life balance and increase productivity without reducing employee pay.

Results:

• Improved work-life balance: Employees enjoyed a better balance between their professional and personal lives, contributing to their overall well-being.
• Boosted retention: The company experienced lower turnover rates, indicating that employees had new work schedules.
• Increased productivity: The improved employee satisfaction led to significant boosts in productivity. Employees became more focused and efficient during working hours, contributing to higher productivity.
• Increased profit: The company's profit increased, demonstrating that the new schedule positively impacted its bottom line.
• Positive company recognition: In 2015, the firm received the Wellbeing Award at the Federation of Small Business Awards for its ethical treatment of staff and innovative wellbeing​.

2. Advanced RV

Advanced RV, a company based outside of Cleveland, Ohio, specializes in customizing Mercedes cargo vans into luxury RVs. They ventured into a 4-day workweek to enhance efficiency and employee satisfaction. The transition was part of a global trial involving over 200 companies aimed at maintaining productivity on reduced hours.

Results:

• Initial productivity dip: At the beginning of the implementation, productivity slightly decreased as the company and its employees adjusted to the new schedule. However, after a year and a half into this experiment, the company has nearly recovered from the initial productivity losses.
• Sustained output: Over time, the company maintained its production levels despite the reduced working hours.
• Positive employee feedback: The workforce well-received the transition, even those initially concerned about the new schedule.

Focus on quality:** Despite the shorter workweek, the quality of work remained high, with a strong emphasis on detail and craftsmanship in their custom RVs.

3. Watford Control

Watford Control, a Northamptonshire-based manufacturer specializing in producing voltage stabilizers and power conditioners, transitioned to a 4-day workweek in 2019. The new schedule involved factory-floor staff working 9.5 hours daily from Monday to Thursday with Fridays off. However, the administrative staff continue to work regular Monday to Friday hours, with Fridays as a remote workday to cater to overseas clients.

Results:

• Increased turnover: Despite a 20% reduction in manufacturing time, the company saw a 30% increase in turnover and a 50% increase in profit margins. This was attributed to improved productivity and a happier workforce.
• Employee well-being Employees benefited from a better work-life balance, with reduced travel costs and lower emissions, as well as well-being, overall job satisfaction, and retention.
• Attracting talent: The innovative schedule made Watford Control a more attractive employer, resulting in more job applications.

Wrapping Up

To sum up, a four-day workweek isn't suitable for all industries and presents specific challenges in manufacturing. Reducing the workweek could slow production rates for tasks requiring fixed completion times.

However, several strategies can address this, such as automation, shift adjustments, lean manufacturing practices, cross-training employees, and optimizing workflow.

Interested in the four-day workweek? Check out our job board. Our platform provides a wealth of job listings that connect you with employers embracing the four-day workweek model.