faces of the frontline: manufacturing’s all stars

Erwin Araujo is a maintenance technician at Xlear in American Fork, Utah, but his proactive approach saw him quickly expand his job responsibilities beyond the production lines. When Xlear grew and added more products to its catalog, Erwin quickly took it upon himself to empower the team with key technical skills to keep operations running smoothly. 

Using Redzone’s Reliability Module, he created maintenance and troubleshooting tutorials that have since slashed downtime and increased team productivity. Thanks to Erwin’s drive for excellence, Xlear today enjoys a culture of learning and empowerment that keeps pushing the boundaries of what’s possible.

From Maintenance Technician to a Training Trailblazer

When machines broke down in the past, very few people had the technical know-how to repair them. However, as a maintenance technician, Erwin was perfectly positioned to troubleshoot and resolve issues promptly. When he joined Xlear, he quickly recognized an opportunity to improve efficiency by teaching repair skills to other machine operators. He particularly stepped up as a trainer when the company brought in Redzone, and he began creating video tutorials to provide clear, step-by-step instructions on addressing common technical issues.

Erwin didn’t work in a vacuum, though. Whenever a recurring issue arose, he stopped operations momentarily, gathered the team, and turned the problem into a learning opportunity. He invited team members to participate actively in the video creation process to make the training more relatable and practical. He also sought ongoing feedback from his colleagues to refine and improve the tutorials. 

This iterative process not only enhanced the quality of the videos but also reinforced a culture of continuous improvement within the team. “Erwin has done a really good job on just getting together with either a group of our operators or individually and guiding them through the entire process of how to troubleshoot stuff, of how to create content for this module,” says (person, position). 7:08

Erwin’s video tutorials have become an invaluable resource for the maintenance team as they can now access on-demand and up-to-date content anytime. They have also reduced the onboarding time for new hires, provided a valuable reference tool for seasoned employees, and minimized machinery downtime. 

Erwin also turned to Redzone to help standardize procedures, track performance metrics, and identify areas for improvement. His analytical approach helped bring impressive improvements at Xlear, including a 68% increase in productivity and a 50% increase in machine uptime. Erwin’s focus on empowering his team has also helped reduce maintenance response times from 60 minutes to just 15 minutes.

Recognizing and Empowering Team Members

As a natural leader, Erwin understands the importance of mutual respect and encouragement for building a thriving workforce. As a result, he has made it a priority to acknowledge his colleagues’ hard work every time they demonstrate an initiative or solve a problem.

This can be as simple as verbal praise during a team huddle or as significant as featuring colleagues in one of his training videos. “It’s kind of nice because now people know that if they make a difference, it’ll make a change and people will see it,” says (person, position) 35:51 This approach not only boosts morale but also encourages a culture of excellence and continuous improvement.

Erwin also uses training videos as a platform to showcase the skills and expertise of his colleagues. Employees are often invited to demonstrate procedures or share their tips and tricks on camera, like the “Tape Change” video where team member Idian demonstrated a tape change while Erwin narrated the process. 

On the other hand, Erwin treats challenges and setbacks as learning opportunities. When a problem arises, he works with his team to analyze the situation, identify solutions, and implement improvements. This constructive approach fosters a growth mindset, encouraging employees to take risks, learn from their experiences, and continuously strive for better results.

Personal Qualities and Skills

Erwin’s role as a trainer has also showcased his remarkable ability to connect with people. His patience and approachable demeanor make him an effective mentor who’s always available to answer questions, provide guidance, and offer support. This has helped create a learning environment where employees feel comfortable seeking help and sharing ideas. 

His bilingual skills in English and Spanish have been particularly beneficial in a diverse workplace. With many of Xlear’s workforce being Spanish-speaking, his ability to communicate with everyone has been essential for crossing language barriers and fostering a more cohesive and collaborative working environment.

Erwin’s unwavering dedication to his work is evident in everything he does. He remains calm and composed in an environment where technical challenges often lead to frustration. He’s patient and approachable, explaining processes thoroughly so that everyone understands the tasks at hand. His willingness to help has made him a go-to person for advice and assistance, building a supportive atmosphere where the team can learn and grow professionally. “He’s encouraging and a great teacher, and he’s extremely patient when showing (his team) these skills,” says (person, position) 42:22

He’s an innovative problem-solver, constantly looking for new and better ways to improve processes. Erwin’s initiative in creating training videos, for example, demonstrates his ability to think outside the box and leverage technology to enhance learning and streamline troubleshooting. This has also encouraged team members to stretch their comfort zones and learn new technology and skills.

Creating a Positive Work Environment that Benefits Everyone

Erwin’s desire to step outside the confines of his initial job description has not only enhanced his career but has also significantly contributed to Xlear’s success and growth. His Redzone training videos and his ability to involve the entire team have improved the team’s know-how and built a strong sense of community and shared purpose. 

His achievements highlight the power of innovation and teamwork in driving operational excellence and employee engagement. Erwin’s story is an inspiring example of how one individual’s initiative and creativity can lead to substantial improvements in operations and employee development. His dedication, patience, and ability to connect with others have made him an invaluable asset, enriching the company culture and driving the team toward continued success.

Want to know more? Read about more Faces of the Frontline, and their stories stories in our ebook.