How eLearning helps manufacturers reduce safety incidents by 27%

Learning Can’t Stop Production On the manufacturing floor, every minute counts. In his conversation with Dr. Conrad Gottfredson, Sivaram Jambunathan shared how his team embedded workflow learning directly into daily operations so employees learn without slowing production. By using the 5 Moments of Need® and the EnABLE methodology, they built systems that close skill gaps in real time while mproving safety, retention, and time-to-competence. It’s not about training before work anymore. It’s about learning while doing it. How is your organization handling “can’t-stop” work environments? Drop a comment below or DM me if you’d like to see what workflow learning could look like in your setting.

Learning Can’t Stop Production On the manufacturing floor, every minute counts. In his conversation with Dr. Conrad Gottfredson, Sivaram Jambunathan shared how his team embedded workflow learning directly into daily operations so employees learn without slowing production. By using the 5 Moments of Need® and the EnABLE methodology, they built systems that close skill gaps in real time while mproving safety, retention, and time-to-competence. It’s not about training before work anymore. It’s about learning while doing it. How is your organization handling “can’t-stop” work environments? Drop a comment below or DM me if you’d like to see what workflow learning could look like in your setting.

Is the Root Cause Always the Operator’s Fault? 🤔 In many manufacturing industries, when a problem arises, the first reaction is often: 👉 “It’s the operator’s mistake.” But let’s pause and ask: Did the operator receive proper training? Were the work instructions clear and practical? Was the machine maintained properly? Did the design/process consider human limitations? Was the environment supportive (tools, fixtures, ergonomics, supervision)? 🔑 True root cause analysis looks beyond blaming individuals. If every issue is attributed to the operator, we miss opportunities to improve processes, training, design, and systems. ✅ Instead of blame → focus on system improvement. ✅ Instead of pointing fingers → ask “why” until the real root cause is revealed. ✅ Strong organizations build a culture of learning, not blaming. Because remember: Operators work within the system we design. If the system is weak, mistakes will repeat.

Now’s days I was thinking about this superb tool, then came into mind I should share here. ****Dear professionals working out there, it’s a collective approach not any individuals or specific department’s KRA KPIs.**** Eight Pillars of TPM – Building a Culture of Zero Breakdown & Maximum Efficiency! In the world of manufacturing, efficiency and reliability define success. That’s where TPM (Total Productive Maintenance) plays a vital role — ensuring that machines, manpower, and methods all perform at their peak. TPM stands tall on 8 strong pillars, supported by the foundation of 5S — just like this temple structure 🏛️ ****** 1️⃣ Autonomous Maintenance (Jishu Hozen) ➡ Operators take basic responsibility for cleaning, inspection, and lubrication. ➡ Result: Prevents small defects from becoming major failures. When operators perform daily 10-minute checks, equipment life can improve by 20–25%. ****** 2️⃣ Focused Improvement (Kobetsu Kaizen) ➡ Aim: Eliminate chronic losses. ➡ Target: 0 losses in production, quality, and safety. Example: If a machine has 10 hours of downtime/month, through root-cause analysis & Kaizen, it can be reduced to 2 hours — an 80% improvement! ****** 3️⃣ Planned Maintenance ➡ Scheduled maintenance to prevent unexpected breakdowns. ➡ Machine history + predictive analysis = 0 unplanned stops. Target: MTBF↑ (Mean Time Between Failure) and MTTR↓ (Mean Time to Repair) ****** 4️⃣ Quality Maintenance ➡ Goal: Detect & prevent defects at source. ➡ Tools: Poka-Yoke, Root Cause Analysis, and SPC. Result: Reduction in rejections and defects by up to 90%. ****** 5️⃣ Early Equipment Management ➡ Feedback from operators during equipment design. ➡ Ensures new machines are more reliable, maintainable, and productive. ****** 6️⃣ Education & Training ➡ Builds multi-skilled workforce capable of handling any challenge. ➡ “Train to sustain” philosophy — ensuring people know why and how things work. ****** 7️⃣ Safety, Health & Environment (SHE) ➡ “Zero Accident, Zero Pollution, Zero Health Issues.” ➡ Safe workplace = motivated and productive team. ****** 8️⃣ Office / Administrative TPM ➡ Streamlines support functions — procurement, planning, logistics. ➡ Reduces lead time and improves communication flow. ****** ⚙️ Foundation: 5S (Seiri, Seiton, Seiso, Seiketsu, Shitsuke) Clean, organized, and disciplined workplace is the base of all TPM activities. 📊 TPM Performance Example: Parameter Before TPM After TPM Improvement OEE (Overall Equipment Effectiveness) 60% 85% +25% Breakdown Time 10 hrs/month 2 hrs/month -80% Rework/Defect Rate 5% 0.5% In result:- TPM = Zero Breakdown + Zero Defect + Zero Accident It’s not just maintenance — it’s a habit/culture of continuous improvement.

Have you ever received a Written Customer Complaint? 😬 (some) Complaints are already hard to deal with... ...but Written Complaints come with their own set of challenges. 💥 Customers can misread your tone 💥 Your reply might come across as cold or defensive 💥 And empathy? It’s much harder to show Tomorrow, I’ll share: ✅ 3 Practical tips on how to resolve written complaints with Empathy. ✅ Practical examples on how to turn robotic/template replies into warm messages. If you or your team deal with written complaints, this newsletter is for you! Join over 1,700+ professionals here: www.hodostraining.com (Scroll to the bottom of the page to subscribe with your name and email) Hodos Training

If anyone is interested in developing their skills in Process Optimization (Manufacturing), a quick thought based on my experience that might be helpful. 💬 Here are some tips for developing this skill: Over the past few months, I’ve learned that process optimization isn’t just about fancy tools or complex equations it’s about understanding how things really work and finding better ways to do them. Here are a few tips that have helped me along the way: 1. Understand the process first. Take time to learn every step, from raw materials to the final product. When you know the “why” behind each stage, spotting inefficiencies becomes easier. 2. Ask questions lots of them. Don’t be afraid to ask why something is done a certain way. You would be surprised how often “we have always done it like that” hides improvement opportunities. 3. Pay attention to data. Keep an eye on process variables like flow rate, temperature, and yield. Patterns in the numbers often tell you what’s really happening in the system. 4. Work with the people on the ground. Operators and technicians usually know the process better than anyone else. Listening to them can give you insights you won’t find or not understand in manuals. 5. Start small, think long-term. Even small tweaks can make a big difference over time a little improvement in efficiency today adds up down the line. 6. Keep learning. Read, watch, experiment, and ask questions. Every process can be improved, but it takes curiosity and persistence to see the opportunities. At the end of the day, process optimization is less about perfection and more about progress. Keep observing, keep learning, and keep improving.

Is the Root Cause Always the crafts Fault? In many manufacturing / Maintenance industries, when a problem arises, the first reaction is often: "It's the Craft man / Worker mistake." But let's pause and ask: Did the Worker receive proper training? Were the work instructions clear and practical? Was the machine maintained properly? Did the design/process consider human limitations? Was the environment supportive (tools, fixtures, ergonomics, supervision)? True root cause analysis looks beyond blaming individuals. If every issue is attributed to the Worker, we miss opportunities to improve processes, training, design, and systems. ✓ Instead of blame → focus on system improvement. ✔ Instead of pointing fingers ask "why" until the real root cause is revealed. ✔ Strong organizations build a culture of learning, not blaming. Because remember: Crafts/ Worker work within the system we design. If the system is weak, mistakes will repeat. Whose Mistake it was? ======== "A worker's mistake is often a symptom - not the cause. The real cause lies in the system that allowed that mistake to happen."

💢 Develop fool proof systems with poka-yoke 🔹️ To develop a foolproof system, you must implement the lean manufacturing principle of poka-yoke, which translates to "mistake-proofing". 🔹️ Poka-yoke aims to eliminate mistakes by designing processes that make it impossible for errors to occur, or immediately flag them when they do. 🔷️ The Poka-Yoke framework for a foolproof system 1️⃣ Identify sources of error The first step is to analyze your processes and identify exactly where, when, and how errors occur. 2️⃣ Implement a "control" system The most effective way to prevent mistakes is to design the process so that it physically or mechanically cannot be performed incorrectly. 3️⃣ Implement a "warning" system If an error cannot be completely prevented, the next best thing is to detect it immediately and alert the user so they can take corrective action. 4️⃣ Establish a "shutdown" system This type of poka-yoke automatically stops the process when an error is detected, preventing further issues. 5️⃣ Integrate management and training Technology and system design must be supported by strong management and training to be truly effective. Standardized procedures: Develop and document detailed operating procedures. This ensures everyone follows the same process, which reduces variability and ambiguity. 6️⃣ Document and track everything Comprehensive documentation is crucial for both training and continuous improvement. 💢 poka-yoke in daily life Implement poka-yoke in your daily activities, to stop mistakes, manage well and live a no stress life” 1️⃣ Make a plan before doing anything. 2️⃣ Make a “to do” list every day. 3️⃣ Put alarms and reminders. 4️⃣ Keep checking yourself and follow up at definite intervals. 5️⃣ Keep activities in strict time control. 6️⃣ Keep optimizing everything. 7️⃣ Keep proper tolerances. 8️⃣ Take self feedback and improve the processes continuously. 9️⃣ Keep learning from others actions and environment. 🔟 Accept the mistake and correct it immediately.

More SOPs won’t save your factory. But what does? Manufacturing teams are facing a knowledge crisis. Experienced workers retire or move on, critical know-how disappears. Most companies respond with more SOPs and training manuals. But here’s the truth: - SOPs are too slow for the pace of the shopfloor - Training content is disconnected from the actual work - New workers get lost between binders, PDFs and verbal instructions The result: long onboarding times, rising error rates and constant interruptions for the few experts left on site. 𝗪𝗵𝗮𝘁 𝘄𝗼𝗿𝗸𝘀 𝗶𝗻𝘀𝘁𝗲𝗮𝗱? Companies integrate training and knowledge capture into daily operations. - Work instructions are based on what actually happens on the line - Guidance is delivered in short, visual formats, right when and where it’s needed - Experienced workers document their know-how in real-time, as part of the task - Skill development becomes measurable, gaps and progress are visible without extra effort This approach makes training part of the work. It’s faster, more scalable, and resilient when teams change. How are you dealing with skill gaps in your operations?

Regulated industries demand training systems that ensure compliance, traceability, and risk mitigation. Dive into how a tailored LMS can support regulated workforces and help you stay audit-ready. Read more: https://zurl.co/TYbn7 #gyrusaim #ComplianceTraining #RegulatedWorkforce #RiskManagement #LearningTech #LMS