Moving to 24/7 Operations? Have You Assessed the Fatigue Risk?
A client recently engaged SHEQ Management to carry out a comprehensive fatigue risk assessment ahead of a major operational change: introducing 12-hour shifts as part of a transition from day operations to a 24/7 production facility.
Extended shifts can improve coverage and efficiency, but they also bring risks that are easy to underestimate and expensive to manage after the fact.
The Risks We Identified
Every roster and site is different, but the key risks for this facility included:
- Reduced sleep quality and fatigue associated with common shift and roster patterns
- Physical impacts of extended working hours on an ageing workforce
- Safety and security challenges during night operations
- Psychosocial hazards, including work-life balance impacts and lone work arrangements
How We Approached the Assessment
To make sure the assessment was thorough and evidence-based, rather than a paperwork exercise, SHEQ Management:
- Reviewed all relevant legislation, codes of practice and industry requirements
- Researched guidance from industry bodies and safety regulators on safer shift and roster patterns
- Conducted one-on-one interviews with affected workers
- Facilitated a workshop with site management and worker representatives
The Result
By engaging an independent specialist, the client received a systematic, impartial review; backed by anonymous worker feedback; that helped them:
- Identify all risks associated with the proposed operational change
- Evaluate the effectiveness of existing controls
- Develop practical recommendations to reduce risks to the lowest reasonably practicable level
Why This Matters
Too often, organisations focus on rostering and productivity without fully understanding the fatigue, health, safety and psychosocial risks that come with extended hours and shift work. By the time these risks show up as incidents, near-misses, or workforce turnover, they're far more costly to address than they would have been at the planning stage.
Is This Relevant to Your Organisation?
If you're considering any of the following, a fatigue risk assessment is worth having on the table early:
- 12-hour shifts
- FIFO roster changes
- Transitioning to 24/7 operations
- Night shift or lone worker arrangements
A professional Fatigue Risk Assessment can help you make informed decisions, protect your workforce, and demonstrate due diligence.
Contact SHEQ Management to discuss how we can help assess and manage fatigue risks before they become incidents.s.