The reason why 'I thought I understood the blade exchange' leads to accidents.
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[New Employee Training Factory] Thought I was teaching, but was it an accident? Avoiding the dangers of blade replacement with a video!
Tool replacement on NC lathes is often treated as a "basic task" on the shop floor. However, this complacency can trigger defective products, equipment damage, and accidents. For example… ● Starting machining with the tool oriented incorrectly, damaging parts or tools ● Insufficient torque causing the tool to shift, leading to dimensional defects ● Machining without correcting the origin, wasting the workpiece Many of these troubles stem from a state of "thinking I understand" because "I was taught once." To ensure daily safety and quality, education that helps workers understand why these checks are necessary is essential. Tool replacement on NC lathes is a typical process that "seems easy but is prone to accidents." Torque, installation direction, and origin correction are all things that can only be adhered to if the reasons are understood. At LinkStudio, we produce numerous video educational materials focused on NC lathes, tool replacement, and machining safety, and we can tailor the content, language, and machine compatibility to meet the educational needs of the shop floor. Companies looking to reduce accidents and lessen the burden of teaching are encouraged to consult with us. *For more details, please feel free to contact us.
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Proposal for Solutions | The Retention Rate Changes with Video Education that Communicates "Why It Is Necessary" The procedure for changing blades is straightforward. However, the lack of understanding among newcomers about "why it is necessary to follow that procedure" leads to accidents. To convey that "meaning," the introduction of educational videos that combine live-action and animation is effective. For example... ● Comparing the correct and incorrect blade installation visually ● Depicting in a story format what kind of processing defects occur as a result of omitting origin correction ● Reproducing actual issues caused by insufficient torque or over-tightening in animation By showing the "causes" and "effects" of such failures through video, understanding and acceptance can be achieved.
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Introduction Steps | Three Steps to Create a Video for Tool Change Training STEP 1 | Organize the causes of near misses and defects occurring on-site Identify the processes where there are many stumbling blocks and accidents during exchanges. STEP 2 | Produce a dedicated video training material for your company Create on-site perspective videos tailored to the target models, work procedures, and work environments. STEP 3 | Incorporate into new employee training and regular training to establish it Regularly utilize the videos to continuously "remind" the training content.
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P3
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Applications/Examples of results
Introduction of Success Cases | "Habitual Confirmation" Significantly Improves Defect Rate and Educational Burden In a certain small to medium-sized manufacturing company, mistakes in tool changes by new employees were occurring frequently. On-the-job training (OJT) could not fully convey the necessary information, placing a heavy burden on the trainers and creating a chronically tense environment on the shop floor. As a solution, video-based training was introduced, leading to the following improvements: ● Tool change mistakes decreased by 80% within three months of implementation ● The proportion of defects caused by "operational errors" dropped to nearly zero ● The OJT time for trainers was reduced from 20 hours per month to 9 hours ● The retention rate of new employees and their proactive confirmation behavior clearly improved In particular, showing what happens when mistakes occur through education was the key to establishing the habit of confirmation.
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| Model number | overview |
|---|---|
| Ideas to Change Awareness through Tool Change Education Practical Point 1️⃣ | Structure it to reproduce the flow of "Mistake → Defect → On-site Trouble" |
| Ideas to Change Awareness through Tool Change Education Practical Point 2️⃣ | Create original videos tailored to the equipment and tools being used |
| Ideas to Change Awareness through Tool Change Education Practical Point 3️⃣ | Make it a short video that can be watched repeatedly, not just a one-time viewing |
| Ideas to Change Awareness through Tool Change Education Practical Point 4️⃣ | Provide multilingual narration and subtitles to ensure it can be understood by foreigners |
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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.
