In the past 150 years, this company has built a portfolio made up of more than 100 global brands. To achieve its goals of manufacturing products that provide great taste, nutrition, convenience, and value for consumers, this customer needed help creating a modern training and upskilling program.

The compounding issues of increasing staff retirements, lack of digitized processes, and lack of formal training program — the company was seeing spikes in quality issues and downtime.

As new frontline employees join, there was no program in place to get them upskilled properly to help meet production demands, and the cycle continued to repeat itself.

The ultimate goal in partnering with Dozuki was to create a world class digital training program across their manufacturing operations. With high numbers of retiring staff and out of date process documentation in paper binders, standardizing and digitizing process documentation was a must.

Sensitive assembly lines for perishable products meant changeover errors were costing the company millions of dollars a year in defects, supply chain issues, and profit losses. A Training Manager reported they lost approximately $3 million dollars a year on just one line due to poor frontline training.

If frontline employees change one little thing incorrectly, it could cause the lids not to be sealed properly, which could explode. Errors like this cause raw material waste and huge profit losses.

Our customer needed a central solution for maintaining changeover processes. Previously all they had was a generic spreadsheet with measurements, but no specific work instructions, tools, or images.

They chose Dozuki because it gave their frontline employees easy and instant access to information from a tablet rather than one person on each shift having knowledge for a single task.

“90% of our issues come from poor frontline training and a lack of documentation,” the Training Manager explained. “Dozuki gave employees a tool to help them fix a jam right away and not have to wait for help. Now the knowledge was all right in front of him. It’s a game changer.”

Initially, Dozuki was launched at one facility. Once results were shown, that facility has become a lighthouse for other additional rollouts across the enterprise.

Prior to launching Dozuki, most employees relied on text heavy information and content, which lacked any visual context or support. Now that processes had photos and videos embedded in them, workers had a visual aid to reinforce processes, reducing the potential for errors.

All frontline operators are granted permission to be authors. If they don’t see something on their site, then they can create a process. Now employees have access to all the information they need to perform their work, rather than one person on one shift having knowledge for one task.

Digital training helped close gaps in basic manufacturing knowledge. This lack of assumed knowledge would have eventually turned into downtime.

But with Dozuki, every process is laid out in an easy to understand, efficient digital layout. There was no question about what their workers needed to do next to be successful.