Alchemy Systems
The Alchemy of Worker Safety

Intertek Alchemy Launches Lean Training Library for All Levels of the Manufacturing Workforce

Monday, June 19, 2023

New Training Courses Connect Frontline Workers and Management with a Common Goal of Identifying and Eliminating Waste

AUSTIN - Intertek Alchemy, announced new training resources to help frontline employees and managers understand and adopt lean manufacturing principles. The new training is part of the company’s Lean Manufacturing Library of eLearning and group training courses, combining instruction for frontline workers, supervisors, and managers to pursue a common goal of improving efficiencies and profits.

Historically, frontline workers have been left out of lean training even though 72% of manufacturers say production would increase and 91% believe their workers would be more engaged in efficiency efforts if they understood lean principles and objectives. Yet only 40% of manufacturers provide lean training to frontline workers.*

The new Intertek Alchemy frontline worker lean training courses close that gap by training both frontline workers and their managers to understand the “why” behind the “what” of lean manufacturing, encouraging them to adopt and accelerate lean principles. The courses provide real-world, practical approaches to identifying and eliminating waste. The Lean Manufacturing Library is part of the Alchemy Training Systems larger course catalog, which includes hundreds of courses in safety, quality, HR, and more for manufacturing companies.

“Lean principles consistently help companies achieve operational efficiencies and improve profits. However, managers and supervisors can’t do it alone,” said Intertek Alchemy President Darrin Harkness. “After all, frontline workers have the most direct impact on production quality and quotas. When employees fully understand lean manufacturing and its benefits, they are empowered to contribute to a collaborative effort that improves productivity and helps companies grow and thrive. It also gives frontline workers opportunities for growth.”

Intertek Alchemy designed its Lean Manufacturing Library courses to be industry agnostic, helping organizations from food manufacturing to automotive plants and more. Training for frontline workers, supervisors, and managers is available under the same package and includes a resource guide so participants can practice what they have learned. Each course comes in English, Spanish, and Canadian French and can be instantly translated into other languages using the Alchemy Training System’s built-in translation and customization plugin.

Training for frontline workers includes:

• Lean: Introduction

• Lean: Waste Types

• Lean: Data Integrity

• Lean: Identifying Solutions

• Lean: 5S Overview

Training for managers includes:

• ABCs of Lean

• Categories of Waste

• Documenting Activities: Value Stream Mapping, Workflow Diagrams

• Examining Data – Spreadsheets, Pareto Charts, Five Whys

• Identifying Solutions – Brainstorming, Fishbone Diagrams

• Identifying Solutions – Kaizen, PDCA

• Implementing Solutions – Kanban, Performance Management Boards

• Implementing Solutions – Line Balancing, Takt Time, Pull Systems, Changeovers

• Implementing Solutions – Workplace Organization

• Verifying Solutions – Standardization, Audits

• The Alchemy of Lean Final Exam

New Research Findings Highlight the Impacts of Frontline Employee Training Practices in Manufacturing

Tuesday, June 11, 2024

Data analysis from more than 1,000 manufacturing and warehouse companies reveals specific actions and characteristics that enable companies to drive greater safety and productivity from their frontline workforce.

AUSTIN, Texas, -- Intertek Alchemy, a global leader in employee training for manufacturing industries, today announces the findings from the Training Methods and their Impact on Workforce Performance in Manufacturing Study, highlighting practices that lead to improved performance from manufacturing employees.

Based on survey responses from over 1,000 manufacturing industry professionals and representing the training programs at more than 3,000 facilities, the findings deliver the most comprehensive research and assessment of workforce training programs in the manufacturing industry.

"Industry leaders utilize the findings of this report to drive meaningful improvements in their operations and create exciting new opportunities for their employees."

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The analysis offers an insight into the practices and characteristics that drive improved business outcomes, as well as the actions which can have a more negative influence on employee safety and productivity. The report also outlines data-driven recommendations for manufacturing companies to strengthen the performance of their frontline workforce and enhance the environment in which they work, leading to greater employee engagement and motivation.

Key findings from the research include:

• 88% of companies that use site-specific images/content in their training material report that their employees have successfully been able to identify and mitigate potential risks or defects.

• On-the-job instruction is present on the manufacturing floor in 73% of facilities, yet 1 in 5 companies believe inaccurate instruction is being provided, and only 14% of companies are very confident in the accuracy of worker-to-worker instruction.

• Companies with cross functional team members on a learning management/training team are 56% more likely to receive accurate worker-to-worker instruction.

• A comprehensive training reinforcement program delivered frequently improves consistent adherence to standard operating procedures on the floor by 215%.

• A mature cross-training program improves employee motivation by 42%, a key feature considering that highly motivated employees are 240% more likely to follow established protocols on the floor.

• Companies with a mature professional development program are 116% more likely to positively influence employee retention.

"We're proud to sponsor research that can provide clear, data-driven answers on how manufacturers can make their working environment safer, more efficient, and more productive," said Intertek Alchemy President Darrin Harkness. "We hope industry leaders utilize the findings of this report to drive meaningful improvements in their operations and create exciting new opportunities for their employees."

The Training Methods and their Impact on Workforce Performance in Manufacturing Study is based on a 57-question survey, developed by Intertek Alchemy and Campden BRI, and was distributed through numerous industry associations.