Why newcomers fail to notice abnormalities in filling amounts | Techniques for reviewing inspection line training
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[Manufacturing Industry New Employee Training] [Video Training] Cultivating Observation Skills to Improve Quality and Safety
"I thought I had checked properly myself." "It was a small difference, so I didn't notice it." From the words of such a newcomer, isn't the issue of the inspection line's "inability to notice abnormalities" becoming apparent? ● An abnormal filling amount (too little or too much) cannot be judged just by looking. ● Although they are "checking," they do not see the "difference from the standard." ● Even the instructors are teaching by "learning by watching," leading to a vague understanding of the standards. This is a sign of insufficient training due to "looking without knowing the points of inspection." Checking the filling amount is not just a matter of visual observation; it is a "judgment skill." To cultivate that skill, education designed from the perspective of newcomers that focuses on "what to look at" and "how to judge" is essential. At LinkStudio, we produce numerous comparative and visual video materials specialized in visualizing inspection points, judgment discrepancies, and quality abnormalities. We invite you to consider video education to transform the workplace from "not understanding by looking" to "understanding by looking." *For more details, please feel free to contact us.
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Proposal for Solutions | Training Design to Teach "Places to Observe" and "Patterns of Abnormalities" through Video Confirming the filling amount is not just about "looking at it," but understanding "what to compare and how to judge." To achieve this, video education that creates a "visually understandable state" by presenting standards and abnormalities side by side is effective. ● Compare appropriate amount, overfilling, and underfilling from the same angle ● Reproduce examples of "subtle deviations" that are easily overlooked with close-up footage ● Clearly visualize judgment points (liquid level, markers, relationship with the container) This approach cultivates the ability for even newcomers to confidently judge, "This is abnormal."
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Introduction Steps | To make the inspection line training "easily understandable" STEP 1 | Organize past missed cases and factors causing variability in inspection judgments Clarify where the judgments diverge and use this as the starting point for guidance. STEP 2 | Create comparison videos using the products to be inspected, showing standard amounts and over/under conditions Structure it to visually input "This is normal" and "This is NG." STEP 3 | Operate the training with a three-part approach of videos + on-the-job training + checklists Ensure everyone has a common perspective through the videos, leading to practical application on-site.
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P3
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Applications/Examples of results
Introduction of Success Case | "Visualization of Judgment Criteria" Leads to a Surge in Inspection Accuracy At a cosmetics manufacturer, there were numerous instances where new employees overlooked "products that appear normal at first glance but are slightly underfilled" when checking containers after filling. The trainers only communicated that "you'll understand once you get used to it," and did not share clear criteria. Therefore, they introduced comparison videos of the filling state and explanatory videos showing "what to look for." As a result of implementing this as a one-minute routine before starting daily inspection tasks: ● New employees' oversights were halved, and the number of mistakes pointed out dropped to zero within a month of implementation. ● Sharing of criteria eliminated discrepancies in judgment among inspectors. ● The burden on trainers was reduced, leading to a more uniform quality of education. The perspective of "teaching how to use one's eyes" significantly improved the accuracy of the inspection line and the efficiency of training.
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| Model number | overview |
|---|---|
| How to create video teaching materials to cultivate a "discerning eye" 1️⃣ | Capture the normal/abnormal filling conditions under the same conditions for easy comparison |
| How to create video teaching materials to cultivate a "discerning eye" 2️⃣ | Emphasize subtle pattern deviations and create awareness of a "noticing eye" |
| How to create video teaching materials to cultivate a "discerning eye" 3️⃣ | Introduce product troubles (leaks, complaints, etc.) that occur when abnormalities are overlooked |
| How to create video teaching materials to cultivate a "discerning eye" 4️⃣ | Clearly indicate "where to look" using subtitles and illustrations |
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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.