Why is Training in Manufacturing So Important?

In recent years, the manufacturing industry has faced persistently high employee turnover rates, with the sector experiencing a turnover rate of 28.6%, significantly above the national average of 3.6% (Deloitte, 2024). While competitive compensation remains a critical factor in employee retention, financial incentives alone are insufficient to sustain workforce stability (Netsuite, 2021). A substantial proportion of frontline workers report feelings of disengagement and dissatisfaction, often attributing these to the absence of a safe and motivating work environment, with 50% of frontline workers indicating readiness to quit in search of better experiences (Beekeeper, 2024). To address these challenges, manufacturers should prioritise the development of effective, scalable on-the-job training programs that enhance employee engagement, motivation, and long-term commitment (Staff Management, 2025).

This article examines strategies for establishing an engaging on-the-job training program tailored to support frontline teams across diverse manufacturing settings.

The Role of On-the-Job Training in Reducing Employee Turnover

Employee turnover in manufacturing extends beyond compensation issues. Primary contributors include misalignment between personal values and organisational culture, particularly among younger workers; diminished motivation stemming from feelings of undervaluation; and limited opportunities for career advancement, leading to perceptions of stagnation (Work Institute, 2023). Engaged employees exhibit lower propensity to resign, as they derive pride from their contributions, perceive their input as valued, and actively participate in organisational success (Gallup, 2023). Meta-analytic evidence confirms that teams with low engagement levels experience turnover rates 18% to 43% higher than highly engaged counterparts (Gallup, 2023). Training emerges as a central mechanism for cultivating engagement, with effective on-the-job programs demonstrably enhancing morale, motivation, and retention (Luna-Arocas et al., 2021).

On-the-Job Training vs. Traditional Classroom Training

Traditional classroom-based training in manufacturing typically encompasses group lectures, textbook instruction, and discussions (HR Dive, 2018). Although valuable for conveying foundational concepts, these approaches prioritise theoretical knowledge over practical application, often resulting in disengagement, rapid knowledge decay, and limited transfer to workplace scenarios (HR Dive, 2018).

In contrast, on-the-job training facilitates learning through direct task engagement and equipment interaction, promoting superior knowledge retention and immediate real-world application (Chen, 2015). This experiential methodology fosters confidence and autonomous problem-solving capabilities (The Employee App, 2025). Empirical comparisons reveal that structured on-the-job training yields higher learning motivation and performance outcomes relative to classroom methods (Chen, 2015). The integration of digital tools further amplifies efficacy, enabling real-time guidance, self-paced progression, and instantaneous feedback, thereby elevating task precision, skill acquisition velocity, and productivity (Jabbar et al., 2022).

Benefits of On-the-Job Training in Manufacturing

1. Easy Implementation

Digital training platforms seamlessly integrate with existing learning management systems, permitting device-agnostic access—including smartphones and tablets—for on-demand support directly on the production floor (Jabbar et al., 2022).

2. Cost and Time Efficiency

Organisations implementing formal training initiatives observe marked productivity gains. Notably, entities with comprehensive training programs achieve 218% higher income per employee compared to those lacking such structures (Devlin Peck, 2025). Digital tools expedite competency attainment by providing immediate access to requisite resources from initial employment (Park and Shaw, 2013).

3. Increased Productivity

On-the-job training accelerates skill mastery, exerting a direct positive influence on productivity metrics (Staff Management, 2025). Research indicates that hands-on learners surpass those dependent on conventional education, accruing practical experience concurrent with task execution (Yadav et al., 2025).

4. Increased Employee Retention

Explicit role expectations and robust training frameworks are pivotal for retention. Employees equipped with clear directives and developmental support demonstrate heightened loyalty and positional success (Luna-Arocas et al., 2021).

Building a Culture of Continuous Learning

As management theorist Peter Drucker (1985) asserted, "Culture eats strategy for breakfast," underscoring culture's primacy in organisational cohesion. In manufacturing contexts, fostering a learning culture engenders employee valuation, engagement, and optimal performance (Harvard Business Review, 2023). Strategies include:

1. Foster Continuous Learning on the Job

While standard operating procedures ensure quality consistency, their efficacy wanes without embedding in ongoing learning processes. Digital platforms enable real-time access to updated instructions, augmenting performance, mitigating errors, and promoting perpetual enhancement (Whatfix, 2023).

2. Crowdsource Knowledge for Training

Frontline personnel often proffer invaluable process improvements. Soliciting feedback, knowledge dissemination, and suggestions cultivates dynamic training and sustains engagement through participatory decision-making (Training Industry, 2024).

3. Encourage Knowledge Sharing and Open Communication

Facilitating insight exchange and best practices, alongside mentoring initiatives and recognition for training contributions, fortifies trust, belonging, collaboration, and procedural refinement (MIT Open Learning, 2023).

A Learning Culture Pays Off

Instituting a learning culture via on-the-job training elevates employee satisfaction while yielding tangible organisational outcomes, including augmented retention through sustained engagement; elevated productivity and quality via skilled execution; fortified interpersonal dynamics fostering cohesion; diminished absenteeism and attrition owing to support perceptions; and bolstered employer branding attracting premium talent (Knight et al., 2017).

Conclusion

Training constitutes a vital investment in manufacturing, with on-the-job modalities substantially curtailing turnover, amplifying productivity, and nurturing continuous improvement cultures (Staff Management, 2025). By prioritising such initiatives, organisations cultivate a motivated, proficient workforce aligned with strategic objectives, transcending mere skill impartation to foster enduring commitment and growth.

References

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Chen, S.-C. (2015) Comparison of the influences of structured on-the-job training and classroom training approaches on trainees' motivation to learn. Available at: https://www.researchgate.net/publication/283788084_Comparison_of_the_influences_of_structured_on-the-job_training_and_classroom_training_approaches_on_trainees%27_motivation_to_learn

Deloitte (2024) 2025 Manufacturing industry outlook. Available at: https://www.deloitte.com/us/en/insights/industry/manufacturing-industrial-products/manufacturing-industry-outlook.html

Devlin Peck (2025) Employee training statistics, trends, and data in 2025. Available at: https://www.devlinpeck.com/content/employee-training-statistics

Drucker, P.F. (1985) Innovation and entrepreneurship: practice and principles. London: Heinemann.

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Jabbar, M.N. et al. (2022) Reskilling and upskilling the future-ready workforce for Industry 4.0 and beyond. Available at: https://pmc.ncbi.nlm.nih.gov/articles/PMC9278314/

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MIT Open Learning (2023) 6 tips for creating a strong corporate learning culture in 2023. Available at: https://openlearning.mit.edu/news/6-tips-creating-strong-corporate-learning-culture-2023

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Training Industry (2024) Building a learning culture for continuous employee growth. Available at: https://trainingindustry.com/articles/performance-management/building-a-learning-culture-how-companies-can-foster-continuous-employee-growth/

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