Training Systems · Example Cards

One task. Three levels. Printed for the floor.

These are real example cards from our training system, shown for one everyday task: wrapping a pallet. Level 1 gets a new worker producing safely. Level 2 sets the quality standard. Level 3 turns your own people into the trainers. Production cards add a photo at every step.

The cards speak your workforce's language.

Switch the cards below. Spanish and Somali are shown as examples; production cards are translated for the languages on your floor.

Task: Pallet Wrap, Manual

Hand wrapping with a roll of stretch film. Looks unskilled. It isn't, and that's the point: if this task has levels, every task on your floor does.

Level 1 · PerformerRed hat
Pallet Wrap, Manual
Before you start
  1. Stack is square. Nothing hangs over the pallet edge.
  2. No crushed or open boxes. If you find one, tell a blue hat.
Wrap
  1. Tie the film tail to a pallet corner, never to the product.
  2. Two full wraps at the base. The film must catch the pallet.
  3. Spiral up. Each pass covers half of the one before it.
  4. Two full wraps at the top, then one pass back down.
  5. Tear the film and press the tail flat. No loose tails.
Check
  1. Push test: press the top corner hard. The load must not shift.
Sign-off: Wrap 3 passing pallets in a row while a blue hat watches.
Level 2 · StandardOrange hat
Pallet Wrap, Manual
Adds to Level 1
  • Wraps to spec at production speed, without prompting.
  • Adjusts wrap count and tension for the load. Light or crushable loads get gentler film and more passes.
  • Refuses to wrap a bad stack. The problem goes upstream, not under the film.
  • Uses the film the spec calls for. Film is money.
Sign-off: Holds the standard across a full shift, verified by a trainer.
Level 3 · TrainerBlue hat
Pallet Wrap, Manual
Adds to Level 2
  • Teaches from the card exactly. No personal shortcuts.
  • Runs sign-offs: three passing pallets in a row, observed.
  • Can explain the why behind every step on the card.
  • Spots and corrects the common bad habits before they spread.
Sign-off: Certified by the program lead.

Task: Stretch Wrap Machine

A semi-automatic turntable wrapper. Same system, but a machine adds the thing plants bleed money on: settings and faults. Watch where the levels draw the line.

Level 1 · PerformerRed hat
Stretch Wrap Machine
Before you start
  1. Turntable area is clear. No people, nothing loose.
  2. Settings match the posted chart. If they don't, get a blue hat. Never change them yourself.
Run the cycle
  1. Center the pallet on the turntable.
  2. Tie the film tail to a pallet corner, never to the product.
  3. Stand clear and press START. Watch the whole cycle.
  4. When the cycle ends, cut the film and press the tail flat.
If something goes wrong
  1. Film break: press STOP, wait for a full stop, re-thread, restart.
  2. Load leans, or the same fault happens twice: STOP and get a blue hat.
Check
  1. Push test: press the top corner hard. The load must not shift.
Sign-off: Run 3 passing loads in a row, including one film-break recovery, while a blue hat watches.
Level 2 · StandardOrange hat
Stretch Wrap Machine
Adds to Level 1
  • Selects the recipe for each load type from the posted chart.
  • Adjusts tension and wrap counts within posted limits, never by feel.
  • Reads the output: loose film means under-tension, crushed cartons mean over-tension.
  • Clears common faults alone. Guards, electrical, and repeat faults go to a trainer.
Sign-off: Holds the standard across a full shift, verified by a trainer.
Level 3 · TrainerBlue hat
Stretch Wrap Machine
Adds to Level 2
  • Certifies operators, including a staged film-break recovery.
  • Keeps the settings chart current, working with maintenance.
  • Can explain why Level 1 never adjusts: one small tweak repeats on every load until someone notices the damage.
  • Stops the classics: riding STOP instead of fixing stacking, or creeping tension up to hide a bad stack.
Sign-off: Certified by the program lead.

These examples are simplified for the web. Production cards carry a photo at every step, your plant's own machines and specs, and a Level 4 owner who keeps every card current as equipment and materials change.

Pilot Program

Start with one line.

A pilot covers one work area: we break 5 to 10 of your tasks into cards, design your level structure, and certify your first trainers. If it doesn't change how fast your people come up to speed, stop there.

Ask About a Pilot