Challenge
A major steel producer faced severe workforce attrition as experienced technicians approached retirement while modernization introduced advanced automation and digital monitoring. New hires lacked required mechanical, electrical, and process knowledge to maintain continuous‑run equipment. Documentation was inconsistent, and skill expectations were unclear.
Solution
A long‑term workforce development strategy: comprehensive JTAs across roles; performance‑based exams to validate readiness; hands‑on labs covering electrical systems, hydraulics, alignment, lubrication, welding, troubleshooting, PLC fundamentals; structured apprenticeship and certification programs; and updated system manuals and equipment documentation.
Outcome
A sustainable pipeline of technicians trained to modern mill standards; reduction in downtime related to skill gaps; faster onboarding; improved safety performance due to standardized procedures; and preservation of institutional knowledge.
Other Case Studies
