Case Study: Toyo Tires cuts overtime 30% with TeamSense

Toyo Tires cuts overtime 30% with TeamSense

Toyo Tires, a 1,500-employee tire manufacturing plant, faced a significant challenge with a 53% attrition rate and reactive overtime costs due to an inefficient, outdated call-out system. Employees had to call a plant landline with a frequently full voicemail box, leaving supervisors blind to shift shortages until production lines were already short-staffed. This lack of visibility drove up costs and created daily operational chaos. To address this, they implemented TeamSense's Attendance Management and Absence Reporting products.

The TeamSense solution provided a text-based system for employees to report absences, giving supervisors advance visibility into crew availability. This shift intelligence allowed the plant to move from reactive to proactive overtime planning, cutting overtime by 30% in the hardest-hit department and triggering a company-wide gain share payout. The data also revealed deeper operational issues, leading to ergonomic improvements and the creation of a new support role. Overall, attrition dropped from 53% to 34.47%, and monthly terminations were reduced by approximately 70%.

Toyo Tires