Shift Handover Workflow Report
Executive Summary
This report documents the current shift handover workflow across Iron Vale's milling floor, identified from the session Trace a Handover Breakdown and supporting incident analysis. Three handoff points account for 78% of communication gaps between day and night shifts.
The visual workflow below maps the as-is process, highlights failure points, and aligns with agreed working agreements from Phase 2 of the engagement.
As-Is Handover Workflow
Key Findings
Handover huddle too short
Average overlap is 4.2 minutes. Machine exceptions and quality holds are deferred to floor discovery.
Inconsistent log completion
Night shift logs completed 62% of the time vs 89% day shift. Missing fields: downtime cause, QC holds.
No shared priority signal
Incoming shift cannot distinguish urgent line changes from routine maintenance without asking.
Strong supervisor relationships
Verbal culture works when both supervisors are present — opportunity to codify, not replace.
Reference Incident
Conveyor stoppage — missed handover · 14 Jul 2026
Night shift conveyor belt tension adjustment was not passed to day shift. Line ran 40 minutes before fault recurred, causing a 2.5-hour production delay. Root cause traced to Step 3 — handover huddle did not include mechanical adjustments.
Recommended To-Be Workflow
Agreed Actions
- Extend handover overlap to 10 minutes with a fixed agenda card at each line station.
- Standardise log fields — add machine status, QC holds, and mechanical adjustments as mandatory.
- Introduce priority board — red/amber/green signals visible at shift change for top 3 line priorities.
- 30-day review — reconvene session to assess IV-8847 class incidents and log completion rates.