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Overtime is a common product of shift work and extended-hours operations, in part because small amounts of overtime are often built into shift schedules. However, if your operation uses additional overtime—that is, over and above regularly scheduled hours—you run the risk of increased costs, fatigue-related accidents and production errors. Developing a sensible overtime policy for your operation is essential and will result in a safer and more productive workforce.
Here are 10 tips for developing an overtime policy that will reduce the likelihood of safety, health and production problems.
1) Beware of the “excessive overtime cycle.” When overtime levels are too high, a counterproductive cycle quickly sets in. Shift workers always feel tired, making them prone to sickness or the need to take a mental health day. Consequently, absenteeism rises, which leads to more overtime and starts a vicious cycle that leads to productivity losses and increased accident risk.
2) Set an annual cap. To prevent an “excessive overtime cycle,” many operations set an annual or monthly cap on overtime hours. A cap benefits employee health and safety and also helps distribute overtime more evenly among the employee population.
3) Account for the “time of day” effect. An annual overtime cap is a good starting point, but it overlooks the effect circadian rhythms have on human performance. Because the human body experiences a low ebb in energy between 3 a.m. and 6 a.m., working during the overnight hours is much harder than working during the daytime.
Owing to this “time of day” effect, it’s advisable to track overtime hours by night-shift hours and day-shift hours. If you use fixed shifts, you might want to have a lower annual cap for night crews than day crews. If you use rotating shifts, you should make sure that no more than half of an individual’s overtime hours accrue during night

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