Engagement snapshot
- Mandate
- Automate the repetitive backfill work without violating labor rules or supervisor control.
- Timeline
- 8 weeks from policy mapping to floor deployment.
- Team shape
- Plant manager, HR lead, 2 automation engineers, and 4 shift supervisors.
The problem
Supervisors handled shift callouts through texts and phone trees, making coverage slow and overtime costs unpredictable.
What we built
Built an attendance exception flow that evaluated union rules, skill requirements, overtime caps, and response order before sending shift offers.
Operating context
The plant could usually cover absences, but the process was noisy and manager-dependent. A single callout kicked off a burst of texts, calls, and ad hoc decisions that pulled supervisors away from the floor.
Key constraints
- Union and overtime rules had to be enforced deterministically.
- Skill requirements varied by line and shift type.
- Supervisors needed override control for exceptional cases.
What we built
Policy-driven offer engine
Ranked eligible employees using labor rules, certifications, overtime status, and shift needs.
Response and escalation flow
Issued offers in the correct sequence and escalated only when the normal path failed.
Supervisor control layer
Kept override and visibility with supervisors while removing the repetitive outreach burden.
Delivery path
Labor rule mapping
Translated union agreements and plant policies into a sequence the system could apply consistently.
Pilot line deployment
Tested on one production area to validate backfill accuracy and manager trust.
Plant rollout
Expanded across lines and shift types while tracking fill time and overtime behavior.
Why it mattered
The flow saved supervisor time because it handled the repetitive offer logic instantly while preserving rule compliance. Coverage became faster, and overtime decisions became more consistent because the process stopped depending on who was on shift.
Implementation notes
- Shift automation lives or dies on labor rule fidelity.
- Supervisors accept automation faster when they keep final override authority.
- The operational gain came from removing interruptions, not just from faster messaging.