Job Shadowing For New Hires

The Job Shadowing For New Hires program is a mandatory onboarding workflow for all newly hired manufacturing operators, technicians, and production associates. It pairs each new hire with a certified trainer (shadowing host) for a defined number of production cycles. The program ensures that every operator is systematically exposed to standardized work sequences, quality checkpoints, and safety protocols before being cleared for unsupervised work. Shadowing logs are reviewed weekly by the shift lead; completion is a prerequisite for permanent operator classification.

This program replaces informal "buddy" systems with a structured, auditable process that directly supports Lean training pillars (Standardized Work, Job Instruction Training). All shadowing activities are recorded and filed in the operator's training record. The program applies to both direct hires and internal transfers entering a new work cell.

This procedure applies to all manufacturing cells, assembly lines, and material handling zones within the organization. It is mandatory for:

• All new full-time, part-time, and temporary production operators.
• Existing operators transferring to a new work cell or process line.
• Contractors and agency workers assigned to production tasks.
• All trainers (shadowing hosts) designated by the shift manager or team lead.

Exclusions: Office-only administrative personnel, salaried management not performing hands-on production work, and visitors on guided tours. In these cases, a general facility orientation is sufficient; this standard work procedure does not apply.

• RULERule 1 – Minimum shadowing cycles. Each new hire must complete a minimum of 5 full production cycles (start-up to hand-off) under direct observation before the first skills assessment. Cycles are counted on the shadowing log and verified by the trainer's signature.
• RULERule 2 – Trainer certification requirement. Only operators who have completed the internal Train-the-Trainer (TTT) program may serve as shadowing hosts. Trainer certification is valid for 12 months and must be renewed annually.
• REQRequirement – Daily debrief. At the end of each shift, the trainer and new hire must complete a 10-minute verbal debrief covering key observations, questions, and safety reminders. A brief note must be logged in the shadowing record.
• REQRequirement – No unsupervised work. The new hire is prohibited from operating any machine or process without the trainer physically present in the work cell until the trainer issues a "clear for supervised work" sign-off on the shadowing log.
• RULERule 3 – Progressive autonomy gates. After cycle 5, the trainer may authorize supervised work (trainer within visual range). After cycle 10, the trainer may authorize independent work after a formal skills demonstration. Gate decisions are documented in the training file.

• Operations Manager – Owns the program; approves trainer certifications; conducts quarterly audits of shadowing logs and completion rates.
• Shift Lead / Supervisor – Assigns new hires to certified trainers; monitors daily debrief compliance; signs off on gate clearances and training progression.
• Certified Trainer (Shadowing Host) – Conducts shadowing sessions; completes daily log entries; performs skills demonstrations; issues gate sign-offs only when the new hire meets standard work criteria.
• New Hire (Operator-in-Training) – Attends all scheduled shadowing sessions; participates in daily debriefs; asks questions and documents personal observations; does not operate any equipment without trainer authorization.
• HR / Training Coordinator – Maintains training records; schedules TTT recertifications; ensures new hire files are complete before permanent status change.