Introduction
In production workshops, it's the men and women who keep the machines running, ensure quality and maintain continuity of operations. Production operator skills represent the fundamental foundation on which a plant's efficiency rests, far beyond the technologies deployed.
France has undergone several decades of de-industrialization, with industrial employment dropping from 5.3 million in 1980 to just 3 million in 2020. This context is accompanied by a shortage of skilled labor, with 60,000 vacancies, and an aging workforce - 25% of the industrial workforce is over 55.
In this changing landscape, developing and tracing the skills of production operators is becoming a strategic issue. The emergence of Industry 4.0 is profoundly transforming the very nature of know-how: a skill now has an average lifespan of 3 years, compared with 30 years in the 1970s.
The essential components of production operator skills
Technical know-how
The skills of production operators are based first and foremost on specific technical know-how, which varies from one sector to another:
- Equipment control Each machine has its own particularities. A cosmetics operator needs to know exactly how packaging lines work, while in the food industry, the emphasis is on manufacturing processes.
- Process compliance knowledge of operating procedures is fundamental. At Valrhona, the skills of production operators include mastery of roasting, molding and coating techniques to guarantee product quality.
- Quality control Quality: operators are often the first line of quality defense. Their skills include the ability to detect anomalies and take appropriate corrective action.
Cross-functional skills
In addition to technical skills, competence includes abilities that make operations more fluid:
- Versatility The ability to work in different positions becomes a major asset. At Shiseidoversatility increased by 34% thanks to proactive skills management
- Adaptability When faced with changes in production runs or production rates, operators need to adapt quickly. This is particularly in demand in the aeronautics and automotive industries.
- Communication The transmission of information between teams is crucial during shift changes. Production operators' skills include the ability to effectively share observations and collaborate.
The regulatory dimension
Competence includes a growing regulatory dimension:
- Electrical approvals Certifications such as B0, H0 or B1 are often an integral part of their skills, even for those who don't work directly on electrical installations.
- Safety certifications These include working at heights, operating machinery (CACES), and sector-specific certifications, which enhance the skills of production operators.
- Quality compliance In regulated industries, competence includes knowledge of standards (ISO 9001, GMP).
These elements of production operator skills require regular retraining, making them more complex to monitor.
The challenges of managing the skills of production operators
Skills traceability
In many plants, production operators' skills are still tracked by hand: scattered Excel spreadsheets, paper documents, or information in team leaders' memories. This fragmentation generates several problems:
- Lack of visibility The need to quickly identify who has what skills is becoming increasingly difficult, especially in the event of absences or peaks in activity.
- Risk of error Without a clear vision, managers can assign people to positions for which they are not sufficiently qualified.
- Painstaking audits Keeping track of training courses can be time-consuming. As a LISI Aerospace quality manager explains: "Before, we had to spend hours compiling information to prepare for audits.
Rapid obsolescence of know-how
Technological developments are considerably shortening the lifespan of production operators' skills:
- Equipment evolution Automation transforms machines, requiring regular updating of skills.
- Process renewal Product lifecycles are becoming shorter, frequently modifying production methods.
- Complexification operations become more sophisticated, broadening the spectrum of production operator skills required.
Faced with this acceleration, it is imperative to regularly update the skills of production operators.
Passing on know-how
The age pyramid poses a major challenge: by 2030, over 43% of industrial technicians employed in 2015 will have ceased their activity. This situation creates an urgent need to pass on the skills of production operators:
- Loss of critical skills Certain aspects of skills, acquired through experience and rarely formalized, risk disappearing with retirement.
- Lack of documentation Many professional gestures are tacit, complicating the transfer of skills to production operators.
- Learning time At Villars Chocolat, developing the skills of a new recruit takes between one and three months, depending on the complexity of the position.
Digitization: transforming the management of production operator skills
Advantages of a digitized skills matrix
Compared to traditional approaches, digitizing the skills matrix of production operators brings tangible benefits:
- Centralization no more scattered data. A digital platform provides a single skills repository. At Exxelia, this centralization has eliminated dozens of Excel files and created a common reference for HR, quality and production teams.
- Real-time visibility Managers can instantly visualize the skills available among production operators, as well as the coverage rates per position and training needs. For Shiseido, this visibility has transformed day-to-day team management.
- Decision support LVMH Fragrance Brands: analysis of production operator skills data helps identify areas of vulnerability. LVMH Fragrance Brands testifies that a digitized matrix facilitates "the rapid identification of critical key skills and training needs".
Automated tracking
Automating the monitoring of production operator skills offers significant advantages:
- Automatic alerts A QHSE manager comments: "I no longer have to worry about keeping track of clearances. As one QHSE manager puts it, "I don't have to worry about keeping track of clearances any more; I get a reminder several months in advance."
- Complete history Each stage in the development of production operators' skills is recorded, creating a history that can be consulted during audits. SEW Usocome particularly appreciated this feature.
- Measurable objectives The platform enables you to define quantified skill development objectives and track their progress.
This automation frees up time for management teams, while reducing the risk of oversights.
Audit preparation and compliance
Regulated industries face strict requirements regarding the traceability of competence:
- Simplified audits immediate access to training history reduces preparation time. Colart has cut the time needed to manage field audits by a factor of four.
- Immediate evidence The ability to quickly present certificates of competence for production operators has become a major asset. At LISI Aerospace, audit preparation time has been divided by three.
- Anticipation By anticipating the expiry of authorizations, the system reduces the risk of non-compliance, which is particularly critical in the pharmaceutical and aeronautics industries.
Developing versatility: a key challenge for production operator skills
Setting clear objectives
Versatility is a strategic aspect of production operators' skills:
- Quantifiable objectives SEW Usocome: the most mature sites define precise targets, expressed as a percentage of jobs mastered per operator. SEW Usocome has formalized targets for each mini-plant.
- Priority zones skills mapping to identify critical areas. At Berry Global, this approach has supported line automation by identifying the skills to be developed.
- Follow-up indicators The skills development strategy is guided by the following criteria: versatility rate, number of trainers per skill or number of critical skills.
For Groupe SEB, this approach has led to a 20% increase in multi-skilling on its sites.
Structured training
Effective skills development requires structured processes:
- Standardized routes Formalized learning stages ensure consistent acquisition of production operator skills. At ValrhonaThis reduced training times.
- Objective assessment Villars Chocolat: evaluation grids are used to validate the acquisition of production operator skills. Villars Chocolat has replaced oral assessments with formal MCQs.
- Enhancing the value of tutoring The identification of experts facilitates the transmission of production operator skills. Exxelia clearly values experts for their transmission role.
These approaches transform training into a performance lever. A training manager testifies: "We have divided training time by 4 thanks to a personalized workflow."
Optimized planning
Precise knowledge of production operator skills revolutionizes planning:
- Relevant assignment operators are assigned according to their skill level. At LVMH Fragrance Brands, "assignment errors are minimized thanks to constraints set when the tool is parameterized".
- Absence management The system quickly identifies who has the necessary skills for a replacement. Shiseido testifies: "I can easily find out who knows how to do what.
- Anticipation Sagemcom's new approach: forecasting production operator skills in relation to production plans enables us to anticipate needs. Sagemcom uses this approach to "place the right person, with the right skills, in the right job".
These optimizations generate significant gains: La Redoute reduced the time spent on planning by 70%, while Bonduelle reallocated three full-time equivalents.
Production operator skills as a lever for commitment
Enhancement and recognition
Beyond the operational aspect, modern management of production operator skills contributes to the development of employees:
- Recognition of expertise mapping highlights the expertise of each individual. An operator at Richemont: "For the first time, my skills are recognized and visible to everyone.
- Promoting trainers The role of experts who pass on their production operator skills has been formalized. At Trigano, this recognition has transformed the way tutoring is perceived.
- Equity Objective criteria replace subjective assessments, reinforcing the sense of justice.
This approach responds to the need for recognition, as was the case for this LISI operator who, after 10 years of involvement, felt forgotten when a change of management took place.
Professional development
The structured management of production operator skills opens up new perspectives:
- Visible routes Colart: operators clearly identify the skills they need to acquire in order to progress. At Colart, each operator can visualize his or her potential development.
- Pro-activity By being informed of their level and objectives, operators become active players in their own development. A site manager confirms: "Employees feel valued and can track their progress."
- Enhanced interviews professional discussions, fuelled by data on production operator skills, are gaining in relevance.
This visibility responds to the aspirations of new generations, who are looking for meaning and progression.
Talent retention
In a context of shortage, retaining skills becomes crucial:
- Reducing turnover A clear management of production operator skills helps to stabilize teams. Trigano saw a noticeable improvement after implementing a structured system.
- Attractiveness The reputation of a company that values production operator skills is an asset for recruitment.
- Membership recognition of skills reinforces identification with the company.
Faced with a sector turnover of 33%, these profits represent a considerable competitive advantage.
Conclusion
Managing production operator skills is no longer a mere administrative function, but a strategic lever. Faced with the challenges of Industry 4.0, generational renewal and the shortage of skilled labor, companies that equip themselves with modern tools to develop and enhance production operator skills give themselves a decisive advantage.
The experience of leading industrial companies shows that the benefits are manifold: time savings, improved quality, regulatory compliance and enhanced commitment. By putting people first, these companies are paving the way for a more agile, more efficient and more human industry.
