Training new hires in the equipment industry is a time-intensive process, especially when onboarding them into process-critical areas such as Basics of Manufacturing, Pyro Processing, and Grinding. These domains involve highly integrated operations — from raw material handling, thermal transformation, to precision grinding — each requiring a deep understanding of engineering, chemistry, and real-time plant coordination.
Traditional classroom-based induction programs often overwhelm new employees with heavy theory and minimal context. Additionally, inconsistencies in trainer delivery and limited access to live equipment further reduced training effectiveness.
Recognizing this challenge, our client — one of the world’s largest cement producers — partnered with us to build a structured, modular Learning program that would dramatically accelerate learning and ensure process alignment across plants.
New hires at the plant were struggling to grasp the end-to-end manufacturing processes—especially in technically demanding areas like kiln operation, clinker cooling, and grinding system controls. Inconsistent knowledge transfer, lack of context-driven learning, and minimal engagement tools resulted in poor retention and increased dependency on senior staff. Additionally, lateral hires with varied prior exposure faced difficulty in aligning with customer’s standardized operating practices, impacting productivity and process consistency.
To address these challenges, we designed and delivered an immersive, modular eLearning program featuring:
