Fatigue is more than just feeling tired—it’s a decline in mental and physical performance caused by prolonged exertion, sleep disruption, and shifts that disrupt the body’s natural rhythm. In manufacturing settings, fatigue can show up as slower reaction times, reduced focus, and poor decision-making, which can affect both productivity and safety.
According to the Conference Board of Canada, roughly 30% of workers report feeling fatigued on most days of a typical workweek. In manufacturing, where long hours, physical labor, and shift work are common, that figure may be even higher.
To protect employees and maintain safe and efficient operations, employers must take proactive steps to manage fatigue among shift workers. Here are some key strategies:
1. Establish a Fatigue Policy
A formal policy helps organizations identify, report, and manage fatigue risks across the workforce. A strong fatigue policy should include:
- Fitness-for-duty checks
- Procedures for temporary task reassignment
- Compliance with federal and provincial working hour regulations
The policy must be clearly communicated, embedded in health and safety protocols, and reviewed regularly to ensure it remains effective.
2. Rotate Tasks and Shifts
Structured rotation helps prevent fatigue from building up.
- Alternate between physically demanding and lighter duties to maintain engagement.
- Vary shift patterns—avoid consecutive night shifts when possible—to support better sleep and recovery.
- Develop rotation plans in consultation with employees while balancing operational needs.
3. Limit Shift Durations
Where feasible, shifts should be eight hours or less, particularly for night work or tasks requiring high concentration.
- Avoid extended shifts unless absolutely necessary.
- Include additional rest breaks in schedules.
- Monitor cumulative hours over weeks or months to ensure workloads stay within safe limits.
4. Promote Open Reporting
Creating a culture where employees feel safe to report fatigue is essential.
- Establish clear communication channels.
- Train managers to respond constructively.
- Protect employee privacy and make timely adjustments to schedules or duties.
5. Ensure Proper Rest
Shift schedules should allow enough time between shifts for sleep, commuting, and personal responsibilities.
- Offer flexible scheduling where possible.
- Collect regular feedback from employees to improve rest opportunities.
- Strictly adhere to federal and provincial rest requirements.
6. Watch for Warning Signs
Supervisors should be trained to recognize early signs of fatigue, such as:
- Slowed reaction times
- Poor concentration
- Irritability
- Impaired decision-making
Regular check-ins, anonymous surveys, and fatigue assessment tools can help identify risks early and prevent potential safety incidents.
Building a Safer, Smarter Workplace
In manufacturing, where long hours and irregular schedules are part of the job, managing fatigue is critical. By implementing structured policies, designing smarter shift patterns, and fostering a culture of openness and support, employers can reduce fatigue-related incidents and create a safer, more productive workplace.
Contact us today for guidance on managing fatigue risks and strengthening your health and safety protocols.