Holding line manning through volume swings and changeovers

The challenge

Absenteeism on individual stations was holding output, and each ramp-up restarted the sourcing cycle from the beginning. Skill category was not consistently matched to the station before deployment.

Aqua solution

Aqua introduced skill mapping ahead of deployment, buffer planning for critical stations, and replacement management so a gap is covered within the shift rather than at the next roster.

Mobilisation & process

Trade requirements were mapped station by station, induction and safety orientation were standardised, and shift supervisors began coordinating manning against the production plan at every changeover.

Measured outcome

Production and HR teams work from a shared view of manning against plan, and headcount scales with the production schedule without restarting sourcing each cycle.