How to Scale Manufacturing Training Across Multiple Locations
Consistent and effective training is crucial for manufacturing companies operating across multiple locations.?
Ensuring that all employees receive the same quality of training, regardless of their location, can be a significant challenge.?
Below we explain how your company can use it, along with examples of manufacturers already seeing success.
But first, let’s explore “the why” of scaling in our industry.
The Need for Scalable Training in Manufacturing
In a multi-location setup, maintaining uniform training standards is essential to ensure that all employees are equipped with the same knowledge and skills. This consistency helps in maintaining product quality and operational efficiency.
Traditional training methods can be inefficient and time-consuming, particularly when scaled across multiple locations. The use of digital tools can bridge this gap, providing a more streamlined and effective training delivery system.
Companies need to digitize their processes and store them in a centralized system. This ensures that training materials are easily accessible and can be updated regularly. Employees across different locations can access the same high-quality documentation, ensuring consistency in training. Here are two success stories, after which we share recommendations for your action plan:
Case Study #1: 90% Faster Onboarding
A Fortune 500 Motion and Control Technology Manufacturer faced significant challenges in training new employees, particularly with the impending retirement of skilled workers. Their previous training methods relied heavily on tribal knowledge and handwritten notes, which were neither sustainable nor efficient. By implementing Dozuki, they transformed their training program, achieving remarkable results.
The company struggled with inconsistent training methods due to reliance on tribal knowledge, a lack of comprehensive backup documentation, and inefficient training processes causing delays and errors. Dozuki’s training tools incorporated videos and photos to enhance communication and process execution, allowing new employees to train at their own pace and providing efficient refresher training. The platform also facilitated discussions among operators on safety concerns, promoting a proactive safety culture.
Results:
Case Study #2: Transforming Training & Upskilling
A Fortune 500 Food & Beverage Manufacturer sought to create a world-class training and upskilling program across their facilities. Their previous reliance on job shadowing and outdated paper documentation resulted in costly errors and inefficiencies. With Dozuki, they were able to digitally transform their training processes.
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The company faced high costs due to poor frontline training and outdated documentation, a lack of digitized processes and structured training programs, and significant losses from changeover errors and quality issues. Dozuki provided a central solution for maintaining changeover processes and delivering instant access to key information via tablets. This digital approach reduced reliance on text-heavy, non-visual content, making it easier for frontline employees to understand and follow instructions.
Results:
Following these success stories, we provide actionable tips for any manufacturer looking to replicate these outcomes and scale effectively.
1. Standardize Training Methods: Transition from handwritten notes, job shadowing, and tribal knowledge to structured digital documentation, ensuring all processes are documented and easily accessible.
2. Implement Digital Work Instructions: Incorporate photos and videos in work instructions, providing visual aids that enhance understanding and retention, and allow employees to train at their own pace with efficient refresher training as needed.
3. Enhance Process Communication: Facilitate discussions among operators on process improvements and safety concerns, promoting a proactive approach to addressing issues and embedding a safety culture into training guides.
4. Leverage Real-Time Data Analytics: Utilize CreatorPro's dashboards to monitor training progress, identify bottlenecks, track performance metrics, and handle nonconformance issues effectively through filtering capabilities.
5. Promote Continuous Improvement: Enable team members to provide direct feedback on processes using, allowing for quicker identification and implementation of improvements, and ensuring training materials and process guides are regularly updated based on feedback and best practices.
7. Ensure Training Consistency Across Locations: Maintain a central hub for all training-related information, ensuring consistency across multiple facilities and utilizing robust document control and versioning capabilities to keep training materials accurate and up-to-date.
8. Drive Cost Savings: Focus on areas that provide significant cost savings, such as reducing changeover times and improving efficiency with connected factory worker tools, continuously optimizing processes to reduce operational costs and improve overall production efficiency.
9. Encourage Visual Insights: Use visual dashboards to highlight pass-fail rates and any failed inspections, providing clear insights into performance and enabling quick identification of areas needing improvement.
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By following these action items, manufacturers can effectively scale their operations, improve training efficiency, and achieve significant cost savings, creating a world-class training and upskilling program that drives operational excellence across multiple locations.