Making On-the-Job Training (OJT) Safer for High-Risk Industries

Introduction

On-the-job training (OJT) is essential in high-risk industries where employees must develop practical skills under real working conditions. Fields like oil and gas, construction, manufacturing, and heavy transport demand not just theoretical understanding, but hands-on experience. However, when lives, equipment, and operations are at stake, unstructured or informal training methods can introduce serious risk. This article explores the challenges of OJT in hazardous environments, and how visual training tools like VR, eLearning, films & animation can reduce danger while increasing learning effectiveness.

What Is On-the-Job Training?

On-the-job training (OJT) is a practical training method where employees learn by performing tasks and responsibilities directly within their actual work environment. This approach allows new hires or existing staff to acquire relevant skills, knowledge, and experience under the guidance of experienced colleagues or managers, often using the same tools, equipment, and processes they will encounter in their roles.

• Training conducted at the workplace

• Helps familiarize new employees through experiential learning

• Used widely in all sorts of industries

• Sometimes involves following a mentor, and sometimes involves doing the work under supervision

Advantages and Disadvantages of On-The-Job Training

Advantages

• Immediate application of skills: Employees can instantly apply what they learn to real tasks, reinforcing knowledge and boosting productivity.

• Contextual learning: Training occurs in the actual work environment, making the learning process more relevant and impactful.

• Cost-effective: OJT often uses existing resources and does not require additional facilities or equipment, reducing training costs.

Disadvantages

• Dependent on trainer quality: The effectiveness of OJT relies heavily on the skills and teaching abilities of the trainer, which can vary widely.

• Risk of passing on bad habits: If trainers have developed poor practices, these can be unintentionally transferred to trainees.

• Disruption to productivity: Training new employees on the job can temporarily slow down productivity as both trainers and trainees may work less efficiently during the learning period.

Types of On-the-Job Training

Coaching: An experienced staff member guides a trainee through tasks step by step, providing support and feedback.

Role play: Employees act out scenarios to practice responding to workplace situations, such as handling emergencies or customer interactions.

Job rotation: Staff are moved through different roles or departments to gain a broad set of skills and experiences.

Shadowing: New employees observe experienced colleagues to understand job routines and best practices.

Examples of High-Risk Work Environments or Industries

High-risk environments are workplaces where the likelihood of harm or injury is elevated due to the nature of the work or the setting. Examples include:

• Construction sites (heavy machinery, heights, hazardous materials)

• Manufacturing plants (industrial equipment, chemicals)

• Oil and gas industry (flammable substances, remote locations)

• Mining operations (underground work, risk of collapse)

• Emergency services (firefighting, law enforcement, medical response)

• Unconventional or isolated workplaces (historic buildings, immersive theatre, lone working

{caption}Screenshot from one of our film dramas for working at heights construction training

The Unique Challenges of On-the-job Training (OJT) in High-risk Roles

High-risk work environments introduce a set of conditions that make traditional shadowing and hands-on learning difficult:

Safety Exposure: New employees may face critical hazards before they’ve fully understood procedures or dangers. Mistakes can have irreversible consequences.

Inconsistent Knowledge Transfer: Without standardized training, information passed from one operator to another often varies depending on the trainer’s habits or interpretation.

Operational Constraints: There’s often limited time to pause work for full training sessions. Production pressures can lead to rushed, incomplete onboarding.

Cognitive Load Under Pressure: New hires must process large amounts of unfamiliar, high-stakes information in fast-paced environments, often under stress.

These factors create a gap between formal training and real-world execution.

The Role of Structured Support in On The Job Training (OJT)

Supporting OJT with consistent materials and delivery systems is crucial in reducing risk. The goal is not to replace hands-on training, but to guide and standardize it.

• Visual Job Aids: Posters, cards, and digital reference tools help reinforce procedures on site.

• Procedure Videos: Step-by-step filmed walkthroughs ensure every worker receives the same instruction, no matter who trains them.

• Pre-job Safety Briefings: Short animations or explainer films covering key hazards and procedures give teams a visual, repeatable foundation before starting live work.

These tools turn informal knowledge into structured, repeatable training moments.

How Visual Training Content Strengthens On-the-Job Training

Visual content adds clarity and consistency to on-the-job learning, especially in high-risk sectors where ambiguity can be deadly.

• Hazard Animations: Realistic scenarios show the consequences of unsafe actions, helping employees understand why procedures matter.

• Explainer Videos: Clear, narrated content demystifies complex tasks, equipment, or safety systems.

• Microlearning Modules: Short, focused eLearning units delivered on mobile devices can support in-the-moment learning, between shifts or immediately before a task.

Visual media cuts through language, literacy, and fatigue barriers, ensuring critical messages are absorbed.

Blending OJT with eLearning and Simulation

Effective On-the-job training doesn’t stand perfectly on it’s own. It works best when paired with modern training methods that frontload knowledge and reinforce best practices.

• Preparation Before Exposure: eLearning or video modules can prepare employees before they enter high-risk areas, reducing uncertainty and danger.

• Simulations and Digital Practice: Where applicable, desktop or immersive simulations allow employees to rehearse tasks and decisions in safe, virtual environments.

• Between-Shift Reinforcement: Mobile-accessible learning ensures employees can revisit key lessons during downtime, travel, or pre-shift meetings.

• Realistic Scenarios: Scenario-based training, particularly using visual formats, helps reinforce procedures by showing them in context, not isolation.

This blended approach bridges the gap between theory and real-world conditions, making OJT safer and more effective.

How New and Emerging Technologies Improve On-the-Job Training

Virtual Reality (VR) and Augmented Reality (AR) are revolutionizing OJT, especially in high-risk industries, by providing safe, immersive, and repeatable training experiences. These technologies offer several key benefits:

• Enhanced safety: Trainees can practice dangerous tasks in a virtual environment without real-world risks.

• Accelerated learning: VR training often results in faster skill acquisition and higher confidence compared to traditional methods. For example, a PwC study found VR learners were 4x faster to train than in classrooms and 1.5x faster than with e-learning.

• Cost savings: Companies can reduce the need for physical equipment and minimize downtime, leading to significant cost reductions.

• Data-driven insights: VR platforms can track every trainee action, providing detailed feedback and helping organizations refine their training programs.

Examples of Companies Using VR for OJT:

• Walmart: Uses VR to train employees in customer service, equipment operation, and handling difficult situations. Their “Walmart Academy” leverages VR simulations to improve performance and customer satisfaction by giving a virtual experiential learning experience to their employees.

• Thames Water: Uses a custom SHIIFT-developed IglooVR project to train and onboard their employees, which resulted in a 57% increase in staff retention and millions of dollars in savings.

VR and AR allow employees to “learn by doing” in a controlled, repeatable setting, which is especially valuable for high-risk roles where mistakes in the real world could have serious consequences.

{caption}Screenshot of Thames Water’s VR Training

Closing Thoughts

On-the-job training is vital in high-risk sectors, but it can’t succeed without structure. The combination of live experience with visual training content, from animation and film to microlearning and simulation, helps companies deliver consistent, effective, and safe training. Supporting On-the-job training with visual tools protects people, standardizes knowledge, and ensures no critical steps are missed when it matters most.

By integrating traditional on-the-job training with new technologies like VR, organizations in high-risk industries can enhance safety, boost learning outcomes, and prepare employees for the challenges of their work environments more effectively than ever before.