Manufacturing Training Solutions and Safety eLearning
For L&D, EHS, HR and compliance teams at manufacturers that need safety, onboarding and procedure training their people will actually use.
We build training from your own equipment, procedures and plant photos, in 40+ languages, and deliver it as packages that run in your LMS.
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- Since 2010Delivering eLearning
- 500+Projects
- 40+Countries with clients
- 120+Specialists
What are manufacturing training solutions?
For L&D, EHS and HR teams, they are custom eLearning courses, simulations and microlearning built from your equipment, procedures and plant photos. IKHYA builds them in 40+ languages and delivers SCORM, xAPI or HTML5 packages for your LMS, so shift workers can complete training and you keep the completion records.
Why manufacturers choose custom eLearning from IKHYA
Built from your plant, not a stock library
Hazard scenes come from photos of your own floor, and steps come from your own procedures. Workers recognize the machines, so the training feels like their job, not a generic video.
Safety you can practice
Workers make decisions in realistic scenarios and get feedback before a mistake can hurt anyone. We build simulation training, including 360-degree scenarios in Adobe Captivate.
One master course, many sites and languages
Keep one source course and localize it into the languages your shifts speak. We work in 40+ languages, with human or AI voiceover.
Records your LMS can report on
Courses publish as SCORM 1.2, SCORM 2004, xAPI or HTML5. Your LMS can then report completions, scores and dates for audits and for your own analysis.
Not sure which option is right for you?
Tell us the topic, the audience and the sites, and we will recommend a format.
What manufacturing teams train on, and what shapes the course
The topic decides the format. Some topics have rules that fix who must be trained and when. The table below shows the ones we are asked about most, with the rule where one exists.
| Training need | What shapes it | Format that tends to fit |
|---|---|---|
| Lockout/tagout (hazardous energy control) | OSHA 29 CFR 1910.147(c)(7) sets different training for authorized, affected and other employees, and retraining when jobs, equipment or procedures change | Role-based paths, with a gamified sequence or scenario for authorized employees |
| Hazard communication (chemical safety) | OSHA 1910.1200(h) requires information and training at initial assignment and whenever a new chemical hazard is introduced | Short modules, then microlearning for new hazards |
| Respirator use | OSHA 1910.134(k) says training must be comprehensive, understandable, and recur annually, and more often if necessary | Annual refresher course with an assessment |
| New-hire onboarding | Site rules, safety induction, role skills and quality standards, all needed before day one on the line | Role-based learning path, with microlearning for each task |
| Machine operation and SOPs | Your own procedures and equipment manuals | Step-by-step scenarios with decision points, or converted instructor-led material |
| Industrial maintenance and electrical training | Your equipment, your procedures and your lockout/tagout rules | Procedure walk-throughs and fault-finding scenarios online, with hands-on practice on the floor |
| Quality, lean and digital skills | Your quality system, improvement routines and new smart-factory tools | Microlearning and blended learning packages |
Online training covers knowledge, procedures and judgment. Practical skills on live equipment still need hands-on practice with a qualified person, and a good course points learners to it.
How lockout/tagout training is structured
Lockout/tagout is a good example because the rule is specific. OSHA 29 CFR 1910.147 covers servicing and maintenance where unexpected start-up or release of stored energy could injure employees. Its training section splits people into three groups:
Authorized employees apply the locks. They are trained to recognize hazardous energy sources, the type and size of energy in the workplace, and the methods to isolate and control it.
Affected employees operate or work near the equipment. They are instructed in the purpose and use of the energy control procedure.
All other employees who work in the area are told about the procedure and the ban on restarting or re-energizing locked or tagged equipment.
Authorized and affected employees must be retrained when their job assignment changes, when machines, equipment or processes create a new hazard, when the procedure changes, or when an inspection or other evidence shows gaps in their knowledge or use of the procedure. The employer must also certify that training was completed and is kept up to date. The standard does not set a fixed annual training date. It does require an inspection of the energy control procedure at least annually.
For eLearning, this means three learning paths from one source, and LMS records that name the employee and the date, so you can see who needs retraining when a procedure changes. Our manufacturing safety training case study shows a gamified lockout/tagout sequence in practice.
Custom eLearning or off-the-shelf courses?
Off-the-shelf courses are the right call for some topics. Custom wins when the course has to match your machines, your procedures or your workers' languages.
| Question | Off-the-shelf course | Custom eLearning |
|---|---|---|
| Does it use your equipment and photos? | Rarely | Yes, built from your plant |
| Does it follow your own SOPs? | General practice only | Yes, built from your procedures |
| Can you change it when a procedure changes? | Only if the vendor updates it | You own the source, so it can be edited |
| Is it a good fit for generic topics every employer shares? | Often yes | Usually more than the topic needs |
| Does it come with an LMS record? | Usually | Yes: SCORM, xAPI or HTML5 |
| What does it take to start? | Fast to buy | Needs SMEs and a scoped project |
Training for multi-site, multi-shift and multilingual teams
Manufacturing teams rarely sit at desks. Training has to work on shared devices, between tasks and for people who speak different languages.
Language is a compliance question, not just a courtesy.
OSHA's Training Standards Policy Statement of April 28, 2010 says employee training required by OSHA standards must be presented in a manner that employees can understand, using a language and vocabulary they can understand. A course in a language a worker does not read well is a gap, whatever the completion record says.
What helps:
Build one master course first, then localize it into the languages of your sites. We work in 40+ languages, with human or AI voiceover.
Test each language version in your LMS before launch.
Use mobile learning that works on tablets and phones, so workers can finish a module during their shift.
Keep the language versions tied to the master, so a procedure change reaches every site. See how this works in our Storyline safety training case study.
What IKHYA delivers
Deliverables
- Learning design: objectives, storyboard and assessment plan
- Interactive courses, scenarios and microlearning
- 360-degree photo and video scenarios built in Adobe Captivate
- Gamified and game-based learning
- Interactive and animated video
- Translation and localization with human or AI voiceover
- Accessible eLearning built to WCAG 2.1 AA and Section 508
- LMS setup, implementation and migration support
- Learning analytics and ROI measurement (xAPI, Kirkpatrick)
Formats and tools
| Category | What IKHYA works with |
|---|---|
| Output | SCORM 1.2SCORM 2004xAPIHTML5 |
| Tools | Articulate Storyline 360Articulate Rise 360Adobe CaptivateLectoraiSpring SuitedominKnow ONEElucidat |
We pick the tool that fits your interactivity needs, your LMS and how often content changes.
How a manufacturing training project works
- 01
Scope
IKHYA and youA kickoff call to agree the audience, sites, shifts, languages, topics, the rules that apply and your LMS. You get a written scope and schedule within 2 working days.
- 02
Gather source material
YouYou send SOPs, equipment manuals, existing slides and plant photos, and name the subject-matter experts (SMEs) and approvers, such as your EHS manager.
- 03
Design and storyboard
IKHYA drafts, you reviewWe write the learning objectives, storyboard and assessment plan around real tasks and risks on your floor, for your SMEs to approve before any build. Two review rounds are included.
- 04
Build
IKHYAWe build one pilot module or scene first, so you can approve the look, feel and interactions, then produce the rest in the agreed tool and your brand style.
- 05
Test and review
IKHYA and youWe test on desktop, tablet and phone and in your LMS or a test LMS, in every language, then you review the finished course. Two review rounds are included.
- 06
Deliver
IKHYAYou receive LMS-ready packages (SCORM 1.2, SCORM 2004, xAPI or HTML5) plus the editable source files, so your team can update the course when a procedure changes.
What drives the cost of manufacturing training
We quote each project, with no standard price list, because these factors change the work:
How manufacturers can measure the results
Completion rates show that people finished. They do not show that behavior changed.
The Kirkpatrick model gives four levels to look at: reaction, learning, behavior and results.
For safety training, the useful signals are on the floor: near-miss reports, observations by supervisors, and incident rates compared with the period before launch. We can set up xAPI and LMS reporting, and agree the measures with your EHS and operations teams before the build starts, so the results can be read after launch.
- 1Reaction
- 2Learning
- 3Behavior
- 4Results
Proof from manufacturing projects
Manufacturing safety
Manufacturing safety simulation: 40% fewer near-miss incidents
A US manufacturer saw 40% fewer near-miss incidents and 200 consecutive zero-harm days after a 360-degree hazard simulation.
- Client and before
- The client has 3 plants and 2,100 floor employees. Before the project, staff watched annual safety videos in groups, and supervisors saw no change in behavior on the floor.
- What we built
- 4 hazard-perception scenes from photos of the client's own plant and a gamified lockout/tagout sequence, OSHA-aligned
- An 18-minute course built in Adobe Captivate as 360-degree scenarios, delivered as SCORM 2004 in the client's LMS in English and Spanish
- 9 weeks, with 3 review rounds with the EHS manager
- How measured
- Near-miss reports in the client's incident log were compared for the 6 months after launch against the 6 months before.
Industrial equipment
One Storyline safety course, 9 languages, live at 14 sites in 5 weeks
A global industrial equipment manufacturer needed one safety course for many sites.
- What we built
- A 30-minute Storyline 360 course with branching hazard scenarios
- Translated into 9 languages with XLIFF, with layouts fixed in the tool
- Voiceover human in 6 languages and AI in 3
- Every language tested in the client's LMS
- After launch
- The course went live at 14 sites in 5 weeks, and the 9 language versions are maintained from one master file.
"Our people now spot hazards in photos of their own press line, not in a stock video. The lockout/tagout game made the steps stick, and near-miss reports dropped within months. IKHYA worked around our three shifts and kept every review round short."
Manufacturing training FAQ
They are courses, simulations and microlearning built for manufacturing teams, covering safety, onboarding, procedures and skills. IKHYA builds them as custom eLearning for your LMS.
Common topics are lockout/tagout, hazard communication, respirator use, onboarding, machine operation, quality and lean routines, and digital skills.
OSHA 1910.147 sets no fixed annual training date. It requires retraining of authorized and affected employees when jobs, equipment or procedures change, or when gaps are found, plus an inspection of the procedure at least annually.
Online courses work well for procedures, safety knowledge and fault-finding decisions. Hands-on skills on live equipment still need practice with a qualified person on the floor.
OSHA's 2010 policy says training required by its standards must be presented in a manner employees can understand. We localize into 40+ languages.
Yes. We convert PowerPoint and instructor-led training to eLearning. Slides usually need a redesign to work well online.
We quote each project. Length, interactivity, media, voiceover, languages, tool, review rounds and LMS testing set the cost.
It depends on the scope, the number of languages and your review speed. Send us the details and we will scope it with you.
Choose off-the-shelf for generic topics you need fast. Choose custom when the training depends on your equipment, procedures or languages.
Look at behavior and results, such as near-miss reports, not only completion rates.
Let us build training your plant floor will use
Tell us the topic, the sites and the languages. We will scope it with you.
