By Dr. Brian Nel, CEO DBCon Global
There is a common mistake that occurs when mines purchase safety training materials. They buy “off-the-shelf” modules.
For example, a mine will purchase a standard “Conveyor Belt Safety” video package. The video is professionally produced. It features clear audio and high-quality animation.
However, when the operators watch this video, they immediately notice a problem. The conveyor belt on the screen looks nothing like the conveyor belt they work on every day.
The tensioning unit in the video is hydraulic. The one on their site is a gravity take-up.
The emergency stop in the video is a pull-wire. The one on their site is a button.
At that moment, the training fails. The operator disconnects because the information is not relevant to their reality.
At DBCon Global, we argue that generic training is dangerous training. Effective training program development must be based on the specific equipment found on your site.
The Research: Adult Learning and Relevance
Research into adult education shows that experienced workers judge new information based on immediate relevance. If they see a discrepancy between the training material and their daily experience, they dismiss the entire lesson.
In the African mining context, this is critical. Many mines operate older equipment that has been modified or retrofitted over the years. A generic training manual based on the Original Equipment Manufacturer (OEM) specifications from 1995 will not match the machine standing in the plant today.
If you train an operator using a manual that describes valves or switches that no longer exist, you are confusing them. You are introducing risk.
The Problem with “Copy-Paste” Curriculums
We often audit training centres where the curriculum has been copied from other operations.
This creates specific technical risks:
- Terminology Mismatch: The training uses one set of names for equipment, while the site staff use a different set of names. This causes communication breakdowns during emergencies.
- Procedural Conflicts: The generic training might instruct an operator to “isolate the main breaker.” However, on your specific site, the Code of Practice requires a sequence of three different isolations. The training directly contradicts the site rules.
- Visual Dissonance: Using diagrams of pristine, new equipment to train staff who work on aged, dusty equipment makes the training feel theoretical rather than practical.
The DBCon Solution: Custom Program Development
We develop training material that functions as a mirror of your operation.
Our development process involves three distinct steps to ensure accuracy.
1. The Technical Audit
Before we write a single slide, we visit the working area. We photograph the control panels. We trace the cables. We identify the specific modifications that have been made to the plant.
We do not use stock photography. If we are training your team on how to start a mill, the picture in the manual will be a picture of your mill.
2. Aligning with the Code of Practice (COP)
Every mine has a specific Code of Practice as required by the Mine Health and Safety Act. Generic training often ignores this.
We build the training module around your specific COP. We ensure that every instruction in the training room matches the legal requirements of your specific license to operate.
3. Simplification and Localization
Technical manuals are often written in complex engineering language. We rewrite this content to suit the literacy levels of the target audience. We focus on clear, imperative instructions. We use local terminology that the workforce understands to ensure the message lands.
The Result: Training That Sticks
When an operator sees their own machine in the training video, engagement increases. They understand that the instruction applies directly to them.
This removes the ambiguity. There is no need for the operator to “translate” the generic instruction to fit their specific machine. The instruction fits perfectly.
Conclusion
Stop spending your budget on generic training libraries that sit on a shelf.
Your mine is unique. Your hazards are unique. Your equipment is unique. Your training program needs to reflect that uniqueness to be effective.
Do your training manuals match your machinery?
Contact DBCon Global to discuss developing site-specific training modules.
