WorkForge Blog

Every Plant Has a Joe. That’s Why Training Is Inconsistent.

Written by Alex Ball | Dec 11, 2025 7:06:13 PM


Every shift has a “Joe.” He’s been there forever and is the one: 

  • Everyone trusts 
  • Who can run any line in his sleep 
  • People turn to when a machine sounds wrong 
  • You lean on when a new hire shows up for training 

Joe is invaluable to your operation — but as a high-performing producer, not as your default trainer. 

When you rely on him to carry your training program, you put his productivity — and your business — at risk. 

Joe may do his job well, but does he teach it correctly? 

When new employees arrive, the plan is almost always the same: 

“Shadow Joe. He’ll show you how things work.” 

But Joe isn’t teaching from a documented, structured, or standardized process. He’s teaching from experience — decades of institutional knowledge built through trial, error, and instinct. 

That’s what makes him exceptional.   But while Joe is your best operator, his training approach isn’t: 

  • Driving consistency across shifts 
  • Available every moment an employee needs training 
  • A substitute for documented role expectations 
  • Scalable as hiring accelerates 
  • Delivered the way the next generation learns best
  • And none of this is Joe’s fault — because you didn’t hire him to be a trainer. 

Inconsistency is everywhere, and it’s not Joe’s fault 

When Joe trains someone, that employee learns Joe’s version of the job.  When the next shift’s “Joe” trains someone, they learn a different version. 

Over time, these small variations become operational drift: 

  • New hires receive conflicting instruction 
  • Operators improvise around unclear expectations 
  • Each shift develops its own “method” 
  • Supervisors spend time correcting avoidable mistakes 

Employees aren’t the problem. Inconsistent training is. 

Shadow-based training drives turnover, slows production, increases safety risks, and keeps you dependent on a shrinking group of individual experts. 

What happens when Joe isn’t there? 

Joe is a phenomenal operator — but he’s also human. What happens when he: 

  • Gets sick? 
  • Takes time off? 
  • Covers another line? 
  • Hits burnout? 
  • Retires or quits? 

When he’s gone, even briefly, the cracks show.   If he leaves permanently all the institutional knowledge he carries — the techniques, adjustments, warnings signs, and “feel” for the equipment — leaves with him. 

A training system centered on one person disappears the moment that person does. 
That’s a risk your business can’t take. 

Consistent training protects your operation — and Joe 

The answer isn’t to replace Joe. The answer is to stop building your training process around him. 

Instead, create more Joes by building a consistent, scalable, modern training program that: 

When consistent training becomes the system, Joe no longer has to be everywhere, fix everything, or train everyone. He gets to be what he truly is: your best operator.   

A final question 

If your Joe unexpectedly left tomorrow — even for a week — how much of your operation could keep running without interruption? 

If that question makes you uneasy, you’re already seeing the need for a consistent, scalable training path that works across every shift — not just the one Joe happens to be on.