How can we solve the problem of "not understanding why it's important to adhere to the exchange timing"?
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[Safety Education Video] "It's still sharp" is dangerous! Methods for knife education to prevent judgment errors.
"I thought it could still be used a little longer." "I didn't replace it because it was still working." Is the judgment of the new employee, who said this, leading to tool damage, defects, and equipment troubles? ● The criteria for judging wear are not understood by the new employees. ● They remember only the "frequency" of replacements, not the "reason." ● Processing defects caused by dull tools are repeatedly occurring on-site. A major reason for this is the lack of focus on "why we need to replace it now" in training. Tool replacement is a critical process that can lead to defects, equipment damage, and serious accidents if the "timing" is misjudged. That’s why it is essential to provide training that helps employees "see and understand" its importance. At LinkStudio, we produce numerous educational materials with narration that allow employees to experience the wear and impact of tools through comparison videos and help establish replacement criteria. Would you like to incorporate training that changes "it's still okay" to "it should be replaced now" into your workplace? *For more details, please feel free to contact us.
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Proposal for Solutions | Educational Design to Show the Impact of Wear through Visuals The timing for replacing cutting tools is not simply a matter of "using them until they are worn out." It is necessary to visualize and teach the effects that even slight wear can have on processing quality, equipment load, and safety. Specifically: ● Show comparative visuals of changes in the cutting surface due to wear progression ● Recreate the changes in "sound," "vibration," and "finish" caused by delayed replacement ● Create a narrative from "neglecting replacement" → "defective products" → "equipment troubles" By doing this, we can shift the perception from "replacement = waste of time" to "an act of protecting quality and safety."
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Implementation Steps | Establishing a Culture of "Adhering to Replacement Timing" STEP 1 | Organize the causal relationship between past defects/troubles and blade wear Specifically pick up the correspondence between wear levels and outcomes. STEP 2 | Create "comparison videos" shot based on different conditions and introduce them into training Achieve "inheritance of senses" and "standardization of judgment" with a structure that appeals to the five senses. STEP 3 | Use reminders before and after work, and repeatedly utilize them within OJT Establish "judgment criteria" within the organization in a way that does not leave it to individuals.
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Introduction of Success Stories | Improving Replacement Compliance Rate by Showing "Changes in Tool Condition" through Video In a metal cutting processing site, a situation arose where shipments were halted due to rough surfaces and burrs caused by a mistake made by a newcomer who judged that "the tool is still usable." To address this, a comparative video was introduced for educational purposes, showcasing processing results based on different wear conditions. By visualizing the causal relationship of "wear → vibration → processing defects → equipment troubles," the following outcomes were achieved: ● Defects due to misjudgment in replacement decisions were nearly zero within two months of implementation. ● The "determination of replacement" that veterans had been doing silently was standardized. ● Newcomers were able to understand and act on the meaning of replacing tools even when they seemed usable. By fostering the judgment of whether "it should be used" rather than "whether it can be used," the safety and quality of the site were stabilized.
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| Model number | overview |
|---|---|
| How to Create Video Teaching Materials for Successful Tool Change Education 1️⃣ | Visually compare the differences in wear condition and finish |
| How to Create Video Teaching Materials for Successful Tool Change Education 2️⃣ | Record actual changes in sound and vibration to allow the senses to perceive the differences |
| How to Create Video Teaching Materials for Successful Tool Change Education 3️⃣ | Structure the process from "Defect → Analysis → Cause is the Tool" in an experiential way |
| How to Create Video Teaching Materials for Successful Tool Change Education 4️⃣ | Visualize the "overall loss" caused by not changing the tool |
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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.