How Effective Training Reduces Human Error in Manufacturing

Did you know that, according to Henkel, “in the global manufacturing industry, human error causes unplanned downtime 23% of the time?“ Pingdom Research discovered that manufacturing sites could lose up to or more than $260,000 per minute, depending on their size and scale. The consequences of human error extend far beyond cost, as they can impact the safety and reputation of your company.

Even with the influx of AI and robots at plants nationwide, skilled techs are irreplaceable. The top technicians are taught not only core skills by their employers, but they also inherit a deep understanding of a wide set of issues and problem-solving abilities. They are trained to lift heavy materials and equipment; organizational skills are also essential. When technicians are properly educated, they adapt to unexpected situations quickly and efficiently, resulting in fewer mistakes and higher-quality work.

Comprehensive training programs, through hands-on experiences and even VR, help employees maintain a deep understanding of standard operating procedures (SOPs).  Clear protocols should be readily available and heavily understood, as SOPs eliminate ambiguity, ensure consistency, and serve as a reference for technicians. On the employer’s end, protocols should not be a “set-up and done” situation; SOPs must be regularly reviewed and updated based on feedback and new technologies to continue optimizing manufacturing practices and ensuring employee safety.

Maintaining a safe and healthy work environment is imperative to preventing human error. When your employees feel comfortable, there’s less physical and mental fatigue, ultimately having a more positive impact on technician health, morale, and retention. If you notice that your employees are struggling and their performance has been impacted, even minor improvements to the workplace, such as proper lighting and anti-fatigue mats, can make a significant difference.

We know what you might be thinking. Training programs, evaluation protocols, and new improvements may sound like a lot of work and expense, but it’s essential to remember that these investments yield significant returns. They work together to create a system that minimizes errors as much as possible. Prioritize these aspects, and you’ll reduce downtime, save money, and maintain the highest level of employee safety.