The Hidden Costs and Risks of Cross-Training Operators

Cross-training process plant operators sounds simple, but execution is often flawed. Human factors engineer Dave Strobhar explains that effective cross-training must be based on job complexity and demonstrated competency — not arbitrary time requirements. Common pitfalls include inconsistent crew procedures that cause negative transfer of training, inadequate alarm management for operators returning to console roles and subjective assessments that fail to verify true proficiency. Decision-making exercises offer a low-cost way to prepare crews for high-stakes, low-frequency events. Looking ahead, Strobhar predicts automation and AI will fundamentally reshape operator roles, demanding more technical knowledge and sharper system-oversight skills from tomorrow's workforce.