"I want to eliminate mistakes!" What educational methods have proven effective in the manufacturing field?
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[Manufacturing Industry New Employee Training] [Training for Foreign Employees] Reduce mistakes by 50% with video training! We will also introduce key points to prevent errors.
In the manufacturing industry, minor oversights and lack of verification often lead to careless mistakes, which can cause quality defects and production losses. According to data from the Ministry of Health, Labour and Welfare, it is said that about 20% of quality defects in manufacturing are due to simple human errors, and furthermore, approximately 30% of all labor accidents are reported to be caused by human error. In particular, in the automotive and electronics manufacturing sectors, there are cases where careless mistakes result in monthly losses ranging from several million to tens of millions of yen. Careless mistakes frequently occur in the following situations: 1. Decreased attention due to the repetition of routine work 2. Lack of understanding of work procedures or incorrect perceptions 3. Weak checking systems that overlook errors 4. Mistakes due to the inexperience of new or foreign workers As these mistakes accumulate, they lead to increased production costs, delays in delivery, and complaints from customers, highlighting the need for effective training to prevent careless mistakes.
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Points to Prevent Careless Mistakes To prevent careless mistakes, the following points are important. For example, Company H successfully prevented the recurrence of mistakes by providing time for workers to review incorrect procedures after training. Additionally, an automotive parts manufacturer implemented a dedicated checklist for processes with frequent mistakes, achieving a reduction in human errors. 1. Incorporate visually clear training to deepen understanding. 2. Use actual mistake cases as teaching materials to provide realistic learning opportunities. 3. Conduct practical exercises after training to enhance proficiency. 4. Provide continuous feedback to establish mistake prevention measures. 5. Regularly record and analyze the occurrence of mistakes to improve the educational program. As demonstrated by Company H's case, utilizing video training has been shown to have a significant effect on reducing careless mistakes and improving quality.
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The First Step in Introducing Training When introducing training to prevent mistakes, it is important to first analyze the types of mistakes occurring on-site and identify which processes are prone to errors. After that, conducting a trial of video training and verifying the understanding of the workers and the effectiveness of mistake reduction will be key to successful full-scale implementation. Additionally, it is important to regularly evaluate the effectiveness of the training and update the content while providing feedback on areas for improvement. This will enable more practical education that adapts to changes in the workplace.
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P3
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Applications/Examples of results
Case Study of Company H - 50% Reduction in Mistakes through Video Training At Company H, a major manufacturing firm, there was a frequent occurrence of mistakes during the product assembly process. In particular, issues arose from incorrect attachment of parts due to operational errors and oversight during final checks. To address this, Company H implemented the following video training program. Specific Content of the Video Training: 1. Recreating past mistake cases through animation to visually convey the issues. 2. Utilizing live-action footage to explain the correct work procedures and checking methods in detail. 3. Learning key points for mistake prevention in a quiz format to assess workers' understanding. 4. Conducting work simulations after the training for practical training. As a result of this initiative, the number of mistakes decreased from 80 to 40 per year, and the defect rate improved by 30%. The data was analyzed based on records from the six months before and after the training implementation, measuring the occurrence of mistakes using work reports and records from the quality control department. To assess the effectiveness of the training, the mistake occurrence rate was compared before and after the training, and a survey was conducted among the workers. As a result, 95% of the workers responded that "awareness of mistake prevention has increased," confirming that the training led to behavioral changes on the shop floor.
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Company information
LinkStudio Co., Ltd. is an animation production company specializing in the creation of training and educational videos for the manufacturing industry. We have numerous achievements on platforms such as Coconala, with **over 3,000 productions and an average rating of 4.9 out of 5**, receiving high praise. Through multilingual support and custom training design, we contribute to reducing the educational burden on the field, standardization, and improving safety.