Manufacturer Reduces Intermittent FMLA Abuse by 60%

The Challenge

A Greensboro manufacturer averaged 140 intermittent FMLA incidents per month — double the industry average — with 73% occurring on Mondays or before holidays. The plant was paying significant overtime to cover absences. HR had no consistent certification, recertification, or documentation process.

The Catapult Approach

Catapult’s FMLA audit revealed the company had never required medical recertification and had approved several vague certifications. Catapult redesigned the entire FMLA administration process — implementing recertification timelines, training HR and managers on permissible inquiries, establishing third-party medical review for questionable certifications, and creating attendance pattern documentation tools.

Results

• ✓FMLA incidents reduced from 140/month to 56/month in 6 months — a 60% decrease
• ✓Monday and pre-holiday absence rates dropped 45% in 90 days
• ✓$280,000 in annual overtime costs eliminated
• ✓18 recertification requests sent — 11 resulted in updated certifications with reduced frequency
• ✓Zero successful FMLA interference or retaliation claims during or after program redesign
• ✓All 22 production supervisors trained on FMLA rights, obligations, and documentation