Semmco Group has introduced a double shift system at its UK manufacturing facility in Woking. This strategic move marks a significant milestone for the business, reflecting both its growth ambitions and commitment to delivering improved service to customers. The transition comes at a pivotal moment. With demand increasing across the UK, Europe and the Middle East, the company recognised that its traditional single day shift model was no longer sufficient to meet customer expectations. Historically, production capacity constraints meant lead times often extended, a long-standing challenge for the business. According to Operations Manager Andrew Redmond, “The shift to a double shift system was essential to unlock additional capacity and support this year’s projected growth”.
Double Shift Manufacturing: Increasing Capacity Without Compromising Quality
The new system introduces a structured two-shift model: an early shift running from 6:30am to 2:30pm, followed by an afternoon shift from 2:30pm to 10:30pm. This effectively extends productive hours without increasing demands on the existing workforce. Importantly, the transition has been carefully implemented to maintain Semmco’s high engineering standards. Semmco’s manufacturing process and its bolted and plated platforms rely heavily on skilled engineers working with complex, bespoke drawings and designs. As a result, the afternoon shift has been introduced gradually, combining experienced team members with new recruits to ensure knowledge transfer and consistent build quality. The result is a flexible production environment. The second shift can pick up directly from the day team, carry out quality inspections, prepare products for dispatch, or support workflow optimisation for the following day. This adaptability has significantly improved operational efficiency. Equally notable is the positive reception from employees. By restructuring working hours, the company has improved work-life balance, helping to retain critical skills.
Lead Times Reduced to as Little as Eight Weeks
The most impactful outcome of the double shift system has been the dramatic reduction in lead times. Within just three months of implementation, Semmco has reduced average lead times to approximately 12–14 weeks. In some cases, the business can now deliver bespoke orders in as little as eight weeks, something that was previously unattainable.
As Andrew Redmond explains, “This shift has transformed how the company supports its customers. For the first time, the operations team can proactively accommodate urgent orders, increasing win rates for our sales team and strengthening competitiveness in the market.”
Supporting Growth, Competitiveness and Future Expansion
Beyond lead times, the double shift system is delivering wider business benefits. It has reduced reliance on out of hours working, improved collaboration between the operations and the sales teams, and created a more scalable production model. There are also gains in quality. With additional time and manpower available for inspection and finishing, the business has seen improvements in product consistency and a reduction in non-conformance issues. Looking ahead, the success of the Woking implementation provides a blueprint for further expansion. The model has the potential to be rolled out across other sites, supporting growth.
For Semmco Group, the move to a double shift system is more than an operational change, it is a strategic step forward. By increasing capacity, reducing lead times, and enhancing quality, the company is reinforcing its commitment to delivering engineering excellence while positioning itself for sustained growth in a competitive global market.
Semmco’s late shift team together at Semmco’s UK manufacturing facility.
