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 articleSCADA systems companies build the screens and software that let operators watch and control a plant. Their engineers spend their time between software desks and customer control rooms, and responsibility after go-live is heavy.

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Share your requirementsA SCADA systems company designs and builds supervisory control and data systems for water, power, process plants and factories. A project begins with understanding the process and the customer's list of signals, then engineers configure screens, alarms, historian and reports, connect to PLCs and field devices, and test against a simulator. Installation and commissioning take place in the customer's control room, often during a plant shutdown or tight window. Once live, the system must be available around the clock, so support engineers take calls out of hours. Engineers need process understanding as well as software skill, and customers depend on the one engineer who knows their plant. Standards of documentation and handover decide whether the customer can stand alone. 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.
Customers phone the engineer who built their system, and when that person leaves or is on leave, support falls apart.
A plant shutdown gives a narrow time to go live, and engineers work long stretches under pressure with no room for delay.
Out-of-hours calls land on the same people, and rest and recognition are unclear.
Handover documents and drawings are written in a rush after go-live, if at all.
A software engineer new to water or power learns the process by making mistakes at a customer's expense.
Software engineers want time to test, field engineers face the plant deadline, and the gap shows up at commissioning.
Start with the topics that matter most here: Organisation Design; Employee Administration; Learning and Development. Then work through the rest. Each topic is written for manufacturing, not in general.
Structure, reporting lines and who is allowed to decide what.
Records, attendance, leave and the day-to-day HR that must simply work.
Training planned from need rather than from the calendar.
How many people, in which roles, by when — and what they will cost.
Requisition to joining, the same way every time.
A first day that is the same for the fifth joiner as the first.
Salary structure, payroll inputs and a month that closes on time.
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.
Who leaves, when, why — and which of them mattered.
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 SCADA systems companies business puts in place, in an order that makes each easier. Open any card for the detail.
A primary and a backup engineer for each live system, with shared notes, so support never depends on one person.
What this coversHideA primary and a backup engineer for each live system, with shared notes, so support never depends on one person. See role design and job descriptions.
A schedule that covers shift handover, rest between long stretches and a backup for each key task.
What this coversHideA schedule that covers shift handover, rest between long stretches and a backup for each key task. See attendance, shift and leave process.
A rota for out-of-hours calls with time off after night calls and clear recognition, checked with a qualified professional for the legal side.
What this coversHideA rota for out-of-hours calls with time off after night calls and clear recognition, checked with a qualified professional for the legal side.
A handover pack that is a stage of the project with an owner and a due date before payment milestones.
What this coversHideA handover pack that is a stage of the project with an owner and a due date before payment milestones. See hr documentation process.
A short learning plan on the plants the firm serves, paired with a senior engineer.
What this coversHideA short learning plan on the plants the firm serves, paired with a senior engineer. See learning and development process.
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.
Primary and backup engineer roles and clear duties so no customer depends on one person.
Commissioning and on-call rosters with rest rules.
Handover and knowledge records written as part of the project, not after it.
Process knowledge plans for software engineers moving into new plant types.
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
A flat structure works until the founder becomes the only route to a decision. How to tell when you have passed that point, and how to redesign without a reorganisation.
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Payroll says one joining date, the personal file says another and the manager remembers a third. How to establish a single trustworthy employee record and keep it that way.
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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 articleMore on the GullyHR blog.
Name a backup for each customer, share notes and let the backup join a visit or two. Review the list every quarter.
Plan the schedule with rest built in, name a backup for each key task and agree who decides if a delay is needed.
A shared rota, time off after night calls and clear recognition. Check the employment side with a qualified professional.
Make it a project stage with a named owner and tie it to a milestone. Review a sample before sign-off.
Pair them with a senior, give short learning on the process and let them shadow commissioning before leading one.
We would list customers against the engineer who knows them, count who has a named backup and see how on-call is shared. A good first piece of work is a primary and backup engineer scheme. Scope is agreed in writing afterwards.
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