Report: 3 Things Today's Workforce Needs for Successful Packaging Operations

Danielle Ohl

Recently PMMI engaged 65 Consumer Packaged Goods (CPG) companies via focus groups to identify and discuss top challenges the modern manufacturing industry faces. Among other topics like the desire for efficient machinery changeover, the 'thinning' of manufacturing, utilizing total cost of ownership when acquiring capital equipment, and packaging machinery innovations that matter most, attendees addressed one of the greatest challenges facing manufacturing today: The difficulty in finding qualified new workers and engaging and developing current employees. Pro Food World's Joyce Fassl puts it most simply, stating that "there aren’t enough candidates available, and incumbents require significant training upgrades." Today we're looking at 3 strategies manufacturers can employ to ensure acquisition and longevity of talent in their packaging operations.

packaging machinery training.jpg1. Turning a Generational Divide into Training Opportunities

The emerging manufacturing workforce of today is greatly different than generations past, with entirely different ethics. No longer living in a world where having a single employer for life is a goal (or even possible), today's younger generation actively leverages their talents and training into new opportunities whenever possible. Loyalty to the employer is still present but needs to be fostered by providing training and growth opportunities, a competitive and comprehensive benefits package, and recognizing work-life balance. The emerging workforce is also well-versed in new technologies and motivated by innovative ideas, however, can sometimes lack the hands-on mechanical experience necessary for this industry. 

On the flip side, the existing workforce, while strong in mechanical and institutional knowledge from decades of experience, lacks the servo and project management training required in today's changing packaging world. Sometimes skeptical and fearful of the newest technologies, this group prefers the adage of 'if it ain't broke, don't fix it.' They have been doing their jobs the same way for many years and can be reluctant to change.

Savvy employers will combine these two often competing generational groups, utilizing the unique skill sets of each in an effort to create a more engaged and better-trained workforce. Existing and 'tenured' personnel can be utilized for training purposes and to pass down the innate mechanical knowledge that they have acquired over many years in the industry. The emerging workforce can, in turn, combine that mechanical knowledge with technology and project management skills to innovate and increase overall packaging efficiencies.

2. Addressing Pervasive Skills Gaps 

packaging equipment problems and solutions.jpg

PMMI's Top to Top Summit Report summarizes the major gaps in packaging equipment training today:

  • Legacy versus new equipment – neither new nor older workers understand the two
  • Local vocational schools are modernizing, but plants are still using older packaging equipment
  • What role technology plays – still need problem-solving skills regardless of technology
  • Comprehensive understanding of packaging equipment needed
  • Fears around technical training, especially electrical controls, need to be addressed

The above training points don't just apply to one portion of the workforce, rather these are overall findings reported by CPG companies that demonstrate the skills gap issues they see as most important for their entire packaging and production department. The main takeaway seems to be this: Equipment and technology training need to be modernized and standardized to ensure long-term employee retention and attraction of qualified candidates.

3. Providing Updated & Simplified Packaging Technologies and Training Opportunities

Technology attracts the newest talent, period. The emerging workforce does not desire to work on outdated and inefficient packaging machinery just because it's the way it's always been done. Modular, clean, progressive production environments and tools make a manufacturing plant much more desirable to the modern employee. They feel they are on the cutting edge of something exciting, which motivates employees to work better and creates intrinsic loyalty to the company providing them the opportunity. 

packaging equipment hands on training.jpgSimple packaging machinery ensures that the learning curve for new hires is much less steep. Training is a costly investment for a manufacturer and can sometimes be inefficient and without standard processes and steps. In many industries, onboarding is treated as something to 'quickly get out of the way', instead of being regarded as a vitally important part of ensuring the long-term viability of the workforce and company in general. 

One way to make training worth the investment is to ensure that the workforce is utilizing current industry information and modern equipment. The longer a manufacturing company operates using outdated packaging technologies, the longer it will take to bring new and current employees up to speed when an equipment update inevitably does take place.

A capital packaging equipment update is a substantial investment, there is no denying that fact. To weigh your options, use the Total Cost of Ownership model to compare current machinery and new packaging equipment side by side. Evaluate the long-term costs of using outdated equipment vs. investing in new packaging technologies. A comprehensive return on investment calculator that allows you to compare current vs. new packaging machinery is also a useful exercise in an effort to determine if a capital equipment acquisition will contribute not only to your operational efficiency but to the attraction and retention of a skilled workforce.

Packaging Automation Return on Investment Calculator Excel