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Skills matrix and cross-training

How a direct team of 11 grew process coverage on a caravan production line, and how cross-training took three job roles to full competency. Names are anonymised.

Skills by operator, direct team of 11

Each radar shows one operator's share of assigned processes at Operating in each area, against the team average. Dot colours mark the coverage bands. Switch to the matrix for exact counts. Team totals match the verified figures. The split by person and by area is illustrative, and operator names are anonymised.

  • All at Operating
  • 80% to 99%
  • 50% to 79%
  • Under 50%
  • Team average

How I developed people

  1. SOPs firstTraining started from the standard operating procedure on the critical processes.
  2. Buddy upEach person was paired with an operative who had years of experience on the process.
  3. Quality auditQuality audits made sure the job was done right.
  4. Widen the skillsOnce someone reached the level the company required, they trained on other processes where the single point of failure risk was highest.

Then the cycle started again, until there were no gaps left.

Evidence behind the numbers

  • Built from scratchBuilt the skills matrix covering 260 processes, 86 of them critical, and led a team of 29.
  • Cross-training that landedThe 3x3 programme took three job roles from about 70% to 100% competency in five months.
  • Coverage you can verifySkills coverage rose from 36% to 86.6% over two years, with 348 of 401 processes at Operating status across my direct team of 11.
  • Engagement in safety108 reports raised through SafetyQube, an EHS management system (102 near misses and hazards, 6 accident reports), which is 33% of the 324 site reports logged from April 2025 to March 2026. All 108 show as closed in the export, 21 of them in one batch on 8 January 2026, so a closed status does not show the risk was removed. One needed investment that the site closure prevented, so the risk was left unresolved.