Why manufacturing employees leave and how to understand why
Operators, technicians and supervisors leave for reasons that sit in shifts, skills and supervision. How to ask, read the pattern by shift and act on it.
6 min readRead articleAn embedded systems company designs the hardware and firmware that sit inside other people's products, and often builds the first units too. The hard part is that a few engineers hold the whole design in their heads.

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Share your requirementsAn embedded systems company designs microcontroller boards, firmware and sometimes the enclosure and test setup for customers who put them inside meters, machines, vehicles or appliances. Work arrives as a customer specification, then moves through schematic, board layout, firmware, bring-up on the lab bench, testing and a pilot batch. Many firms also run a small production or assembly line for the first few hundred units. Teams are small. One firmware lead may know every driver and one hardware engineer may know every board revision. Projects have fixed customer dates, so the last weeks are long. Good engineers are approached by larger product companies all the time. See also HR for manufacturing.
These are the places the people side of this kind of business tends to give way. The rest of this page works through them.
HR here has to work for each of these groups, not only the office. The set-up below is written with all of them in mind.
The firmware lead or board designer often carries undocumented knowledge, and if that person resigns mid-project the customer date is at risk.
Boards that do not boot or sensors that misbehave take engineers deep into evenings, and the effort is rarely recognised in how people are rated.
Technicians who debug with a scope and soldering iron are paid and graded below coders, although projects stall without them.
A specification change after layout sends hardware and firmware teams back to work together, and nobody owns the cost of that rework.
A new engineer takes months to read the codebase and the lab habits, and seniors who mentor lose their own project time.
Larger companies offer fixed roles and brand names, so mid-level engineers compare your project churn with their stability.
Start with the topics that matter most here: Retention and Attrition Management; Learning and Development; Compensation, Payroll and Benefits. Then work through the rest. Each topic is written for manufacturing, not in general.
Who leaves, when, why — and which of them mattered.
Training planned from need rather than from the calendar.
Salary structure, payroll inputs and a month that closes on time.
How many people, in which roles, by when — and what they will cost.
Structure, reporting lines and who is allowed to decide what.
Requisition to joining, the same way every time.
A first day that is the same for the fifth joiner as the first.
Records, attendance, leave and the day-to-day HR that must simply work.
Goals, reviews and ratings that hold up in a conversation.
Named backups for the roles that cannot be vacant.
Communication, recognition and the conditions people actually work in.
Two routes — one for complaints, one for conduct — kept separate.
Policies a manager can apply, and obligations with owners and dates.
Induction, records, incident reporting and follow-through.
Resignation to relieving letter, in a defined order.
Records that survive people, and approvals that do not queue.
A short monthly pack management actually reads.
An HR function that runs the same way every month.
The pieces a embedded systems companies business puts in place, in an order that makes each easier. Open any card for the detail.
A simple ownership sheet for firmware modules, board revisions and test scripts, with a named backup for each.
What this coversHideA simple ownership sheet for firmware modules, board revisions and test scripts, with a named backup for each. See employee information management.
One scale that places bring-up technicians, test engineers and firmware developers by what they can do alone, linked to pay.
What this coversHideOne scale that places bring-up technicians, test engineers and firmware developers by what they can do alone, linked to pay. See compensation benchmarking.
A short review where the engineer explains the design to a second person before the pilot batch, so knowledge is not held by one head.
What this coversHideA short review where the engineer explains the design to a second person before the pilot batch, so knowledge is not held by one head.
A small real task, then a bring-up shift beside a senior, then ownership of a module, with a sign-off at each step.
What this coversHideA small real task, then a bring-up shift beside a senior, then ownership of a module, with a sign-off at each step. The learning and development process shapes this.
A view of which skills each coming project needs, so searches start before the gap.
What this coversHideA view of which skills each coming project needs, so searches start before the gap. The recruitment process consulting work supports it.
Before changing anything, find out what is true today. These checks take an afternoon and tell you which of the topics above to start with.
Share your requirementsConfirm with a qualified professional. What applies to you depends on your business, your state and your arrangements, and it changes. This page describes practice. It does not state a legal position.
The services below fit this kind of business best. Each starts by recording where you stand, and every later report compares against that. We do not promise outcomes.
Keeps the few engineers who hold your designs, with clear reasons to stay beyond the current project.
A staged path that takes a new graduate from reading code to owning a module.
Grades that value bench technicians and firmware developers against nearby firms.
Clear roles for hardware, firmware and test so ownership is not left to habit.
Start with a free conversation, or see the paid HR Diagnostic.
Understand the business, its workforce, current processes and HR challenges.
Find the missing, weak, inconsistent or person-dependent processes.
Create the structure, processes, policies, SOPs, dashboards and systems needed.
Help HR and department managers actually adopt the new system.
Digitise repetitive and approval-based workflows where it is worth doing.
Track hiring, attendance, employee cost, performance, training and attrition.
Strengthen the people-management system continuously, not once.
From the GullyHR blog: one on HR in manufacturing, and one on each of the topics this page points to.

Operators, technicians and supervisors leave for reasons that sit in shifts, skills and supervision. How to ask, read the pattern by shift and act on it.
6 min readRead article
How to spot an unmanageable workload before it becomes an exit or an error, what to look at, how to talk about it and what to change, without guessing.
5 min readRead article
A calendar of courses, a budget spent by March and no record of what any of it changed. What a learning and development process contains when it starts from need rather than from the catalogue.
7 min readRead article
Most salary structures grew one negotiation at a time. How to build grades and bands from what you already pay, without repricing everybody at once.
8 min readRead articleMore on the GullyHR blog.
Ask for a module ownership sheet, pair every module with a backup and make a design walkthrough part of each release. Recognise the mentor's time in how you rate their work.
Record the hours and the problem solved, and look at it in ratings. Without a record, the people who stay late on stubborn boards look no different from the rest.
They can share one scale with different tracks. What matters is that debugging and test skills are written down and paid for, so technicians see a path upward.
Agree a change process with the customer, with a note of what each change costs in engineer days. It protects the team and gives you facts for the next quotation.
Be honest about what you offer: wider ownership, faster decisions and design work end to end. Show a clear grade path and keep the interview process quick.
We would look at which modules and boards only one person understands, how many extra evenings the last project took, and how long new engineers took to work alone. A good first piece of work is an ownership sheet plus a skill grade scale for engineers and technicians. Scope is agreed in writing afterwards.
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