In the rapidly evolving landscape of manufacturing, the significance of knowledgeable and skilled factory workers cannot be overstated. Their expertise plays a crucial role in the success of manufacturing operations. For workers to excel, effective manufacturing training and ongoing workforce development are essential. As organizations transition into Industry 4.0 and prepare for Industry 5.0, innovative training methods are emerging to meet the demands of the future while enhancing workforce productivity.

While many companies have traditionally relied on on-the-floor shadowing and classroom instruction, a growing number are adopting modern strategies that incorporate smart manufacturing concepts, leading to a notable 40% reduction in training time and cost. This article explores how forward-thinking manufacturers are leveraging new technologies to redefine their training practices.

A Better Approach to Manufacturing Training

According to a 2018 Industry Week Survey, shadowing and classroom instruction remain common forms of manufacturing training. However, organizations increasingly find these traditional approaches impractical and ineffective. On-the-floor shadowing, employed by about 75% of manufacturers, pulls experienced operators away from their duties, risking inconsistent training and the potential transfer of bad habits.

Similarly, classroom instruction, used by 39% of manufacturers, often leads to rapid information decay once employees return to their workstations. Consequently, workers are frequently reliant on outdated and incomplete written work instructions, which are difficult to access and follow.

An alternative approach that produces better results is on-the-job training, where operators are equipped with tablets that provide digital work instructions in the form of video micro-lessons at their workstations. This method allows for immediate access to bite-sized information when needed, empowering workers to learn 'in the flow' and apply their knowledge instantly.

As a learning and development coordinator at a leading medical nutrition manufacturer explains, "Operators don't need to learn everything during onboarding because we are confident they can find it when they need it." By facilitating self-paced learning, this manufacturer has successfully reduced shadowing time and manpower costs by 40%, aligning with the principles of a paperless factory.

Stephane Roy, operations support coordinator at Riviera, a Canadian dairy products producer, echoes this sentiment: "Short videos mean employees can watch at any time for simple reminders or execution of tasks." This flexibility signifies a shift towards a connected worker model that supports continuous learning.

Enhancing Workforce Productivity Through Video Micro-Lessons in Manufacturing

One of the most significant advantages of using video micro-lessons over traditional text-based instructions is that video content is generally easier and faster for operators to comprehend. This accessibility enables workers to master new skills more quickly, which is vital in an era defined by Industry 5.0 technologies.

For instance, Duvaltex, North America's largest contract textile manufacturer, reduced the onboarding time for new employees from eight weeks to just four. Similarly, Canam, a manufacturer of steel components, has successfully cut the time it takes for operators to complete training modules by 15%.

A plant controller at WestRock, a global leader in paper and packaging, states, "The video support allows us to eliminate a lot of confusion, loss of time and above all - delays." By integrating training with workforce productivity tools, these companies enhance not only individual skill sets but overall operational efficiency.

Moreover, mobile devices allow operators to access real-time instructions when needed. A leading confectionery manufacturer has reported an impressive 80% to 90% reduction in the time employees require to locate training materials and standard operating procedures.

Streamlining Training Content Creation in Manufacturing Through Video Solutions

Contrary to conventional beliefs, many manufacturers find video-based lessons quicker and easier to produce than their written counterparts. For example, Westrock and Barry Callebaut, one of the largest chocolate and cocoa manufacturers globally, have seen a 50% reduction in the time needed to create training content compared to traditional paper methods.

One key to this efficiency is that any experienced frontline worker or subject matter expert can easily use a tablet device to create a short "how-to" video or demo, whether they are engineers, continuous improvement specialists, or senior operators. This democratization of content creation aligns with the principles of Training Within Industry, fostering a culture of shared knowledge.

While it’s essential for these videos to pass through a formal approval process before becoming standardized practices, the ability to create instructional content directly on the factory floor—a key aspect of the connected factory concept—represents a remarkable shift in the training paradigm.

As a Plant Manager at Arcelor Mittal notes, "Normally, we would write the procedure, but sadly the text format just created more noise around the procedure. A picture is worth 1,000 words."

Fostering Continuous Learning in Manufacturing Through Mobile E-Learning Solutions

To cultivate a culture of continuous learning, manufacturers are also equipping factory workers with mobile e-learning apps that serve dual purposes as communication tools. These technologies keep management and workers digitally connected and foster a strong learning culture where knowledge is continuously shared and developed.

Richard Bilodeau, Continuous Improvement Manager at Barry Callebaut, highlights how real-time communication through a live "factory feed" aids in troubleshooting and maintaining a permanent record of solutions. "Real-time input, in text or video format, is seamlessly transmitted to operators and maintenance teams for immediate reference and action and simultaneously logged for later use. This not only streamlines daily work and collaboration but also enhances employee training."

Arcelor Mittal sees similar benefits, with their plant manager noting, "The video support helps us simulate the step-by-step process and troubleshoot easily. The factory feed ensures that information persists, allowing us to go back and reference it anytime." By integrating workplace safety training and food safety training into this system, manufacturers improve overall safety and compliance.

Real-time communication also empowers label and packaging manufacturers to enhance collaboration among workers. Jonathan Bourbonnière, President at Multi-Action, remarks, "It broke down walls and silos in our company, helping us transfer knowledge more effectively amongst all employees."

An App Designed Specifically for Factory Workers

Central to these success stories is Poka, a web and mobile application tailored for the manufacturing sector. Poka facilitates training, communication and knowledge sharing directly on the factory floor - embodying the principles of a paperless factory and smart manufacturing.

Alongside the enhancements to operational efficiency and training, workers recognize the value of Poka and eagerly incorporate it into their daily tasks. The learning and development coordinator from the medical nutrition company states, "Everyone was on board from the start. Operators are the most excited about Poka because it truly is their system—they utilize it every day. While management can monitor what's happening on the factory floor, it's really for the workers."

Marin Rainville, Plant Controller at WestRock, adds, "Not only have we seen significant time savings, but our employees feel that the training materials produced with Poka greatly simplify their work."

Conclusion: The Future of Manufacturing Training

As manufacturing continues to advance towards Industry 5.0, the landscape of training is also evolving. More organizations are adopting innovative methods that address the needs of their workforce while enhancing productivity and efficiency.

Through the utilization of video micro-lessons, mobile technologies and real-time communication tools, manufacturers can significantly improve their training effectiveness and reduce associated costs.

As these success stories illustrate, the future of manufacturing training lies in continuous learning and adaptability, ensuring that workers acquire the necessary skills to thrive in increasingly complex environments. By prioritizing effective training and knowledge sharing, manufacturers empower their employees and secure a competitive advantage in the marketplace.

By embracing these modern training practices, manufacturers pave the way for a more skilled, engaged and productive workforce capable of meeting the challenges of the future while fully realizing the potential of smart manufacturing and connected factories.

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This article was updated in January 2025 for accuracy.

Manufacturers Share Their Training Success Stories: Embracing Industry 4.0 and Industry 5.0