Case Study

Hot Mix Asphalt
Training Plan

Building a comprehensive training plan for hot mix asphalt plant employees across a geographically dispersed, high-turnover workforce.

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Summary of Project

Building a Comprehensive Training Plan for Hot Mix Asphalt Plant Employees

A global building materials and construction company had hundreds of employees working in hot mix asphalt plants around the country, and no standardized way of training them. After years of working with Blake Learning Solutions to update and develop individual trainings, they approached BLS to consult on designing a comprehensive training plan.

The Challenge

Scaling expertise across a high-turnover, hands-on, geographically dispersed workforce

Working at a hot mix asphalt plant is dangerous and difficult. New employee turnover is high, and many locations are staffed by only a few employees. Without a comprehensive training plan, new employees were mostly relying on the knowledge and time of more experienced employees. In interviews conducted as part of the analysis process, employees expressed being frustrated with not having enough time to receive training. From one plant manager:

"We expect a lot from our new hires and that's why I think we have so much turnover. We hire someone and then we expect them to know everything we know now after being there for twenty years. We don't have the time to train people ourselves like we need to and that frustrates new hires and that's why they leave."

The nature of the work also requires hands-on, experiential learning. Running an asphalt plant cannot be taught through a series of eLearning courses. From an operations manager:

"Our guys are outdoor people, they don't like being in an office. If they are thrown in a room and put on a training video, they will fall asleep. They are very hands on."

Whatever we recommended needed to:

Capture the knowledge and expertise of experienced plant operators
Simplify and standardize the task of on-the-job training
Flex to the different levels of experience and roles across plants
Be easily accessible at remote sites

The Solution

A tiered training plan designed for the realities of plant operation

Blake Learning Solutions analyzed the current state of training through conducting employee interviews, visiting a hot mix asphalt plant, and reviewing existing training resources. From these resources, we were able to outline necessary knowledge and skills, identify training gaps, and recommend appropriate training materials and formats.

Training Categories Mapped Across the 5 Learning Lines/Roles

Our training plan identified five categories for training - Understanding the Company; Asphalt Production; Component Systems and Equipment; Professional Skills; and Health, Safety, and the Environment – across four levels of experience. Within each category at each level, we identified topics to be covered, and training formats appropriate for the topic. We also recommended the development of a mentor program to train the trainers who would be invaluable in passing on their knowledge and experience.

Training topics organized by category and experience level

Recognizing that a training plan means nothing if the training is never developed, we also included a development planning tool to assist with strategy and budgeting. We organized the more than 180 recommended training items into a chart listing the types of training to be developed, cost estimate, and recommended timeline for development.