Optimizing Shift Handover Processes to Maintain Workflow Continuity

Abstract

Inefficient shift handovers at MM Packaging in Manati, Puerto Rico, caused approximately 30 minutes of downtime per transition, reducing productivity in the Printing and Folding departments. The project applied the DMAIC methodology to identify root causes, including inconsistent documentation, poor communication, and delays in equipment handling. Improvement actions implemented a standardized shift handover checklist, structured communication protocols, and organized equipment storage, resulting in a 50% reduction in average handover time, from 30 to 15 minutes. Control measures such as Standard Operating Procedures, supervisory audits, and periodic training ensured the sustainability of improvements. The project demonstrates that structured and standardized shift handovers significantly enhance workflow continuity, reduce downtime, and improve overall operational efficiency in high-volume manufacturing processes.