Safety risks addressed

YOJ Pack-Kraft operates heavy roller machines used in corrugation and lamination, alongside high-voltage equipment. These two zones carry significant risk if procedures are not followed: pinch points, unexpected start-up, and electrical exposure. The goal was proactive accident prevention—not a generic lecture—through high-frequency safe behaviors.

Training design: Behavior-Based Safety (BBS)

This program was built using Behavior-Based Safety principles: focus on observable proactive behaviors, real-time coaching, and reinforcement so safe choices become routine. Before design, I gathered input from floor operators and reviewed past incidents to identify unsafe behaviors and knowledge gaps—such as incomplete lockout/tagout understanding or unsafe tool choices at panels.

Station-based delivery (hands-on)

Employees rotated through training stations. One station used a roller machine mock-up for safe cleaning/adjustments with the machine powered down—reinforcing LOTO as a non-negotiable step. Another station focused on electrical panels, where an electrician coached teams on identifying live circuits, PPE selection, safe troubleshooting, and emergency response.

Real-time feedback (coaching to build muscle memory)

Real-time feedback was central. As participants practiced steps, trainers provided immediate coaching to correct technique. This turned procedural knowledge into muscle memory—an essential outcome when working around rotating rollers and energized systems.

Performance support: QR microlearning refreshers

To sustain learning, short microlearning videos were made accessible via QR codes in the maintenance area. Operators could refresh “how to safely clear a jam” or “checklist before re-energizing a machine” without waiting for retraining.

Outcomes (safe to publish)

While specific numbers are confidential, near-misses and incidents linked to these hazards dropped noticeably in subsequent months. Employees reported higher confidence, and hazard reporting increased—a positive signal of a safer, more open safety culture. This intervention shows L&D maturity: balancing production goals with non-negotiable safety.