A second-shift decision is not based only on staffing and vehicle count. Measure the actual same-day cycle for plate preparation, container washing, loading and shift handover.
Track the required cycle on a round
Record when plates are prepared and placed in the freezer under manufacturer instructions. Note freezer rack capacity, sets ready during the shift and pre-load checks. Looking ready alone does not establish a validated starting condition for the product.
Measure unloading, cleaning and reloading time for containers returning from the first round. Compare second-round demand with actual orders and delivery windows; separate tests where the product configuration differs.
Make shift handover traceable
Use a shared form for transferred orders, container IDs, plate sets, alarms, missed deliveries and delays. If a trial still shows a capacity gap, compare a second set, added washing/freezing capacity or a different round using cost and equipment limits; do not use a universal freeze time or plate count.
