Reducing Machine Downtime With QR Codes at Milwaukee Tool

How Milwaukee Tool Uses QR Codes for Just-in-Time Training

In today’s fast-paced manufacturing environments, even a few minutes of downtime can impact productivity, efficiency, and profitability. At Milwaukee Tool, a company known for its commitment to innovation and its end users, the solution to reducing machine downtime and accelerating employee learning came in the form of something simple yet powerful: QR codes. 

With support from Tooling U-SME, Milwaukee Tool’s Rapid Innovation Center (RIC) rolled out a just-in-time training solution that puts critical knowledge directly in the hands of operators right at the machine. 

The Challenge: Scattered Resources and Downtime 

At the RIC, the team faced a familiar challenge. Machine information was scattered across multiple platforms, making it difficult and time-consuming for operators to troubleshoot problems or complete tasks efficiently. Equipment issues that occurred infrequently posed additional barriers, especially during off-shift hours when support staff weren’t available. 

In a prototyping environment where speed and flexibility are essential, the team needed a streamlined approach to knowledge sharing and a faster way to onboard new employees. 

The Solution: QR Codes Bring Learning to the Work Area 

Working with Tooling U-SME’s Talent & Workforce Services team, Milwaukee Tool developed and deployed a training system that uses QR codes posted directly on CNC machines. Scanning a code gives operators instant access to: 

• Machine overviews 
• Micro-videos demonstrating key tasks 
• Job aids and checklists 
• Troubleshooting guides and alarm code directories 
• Maintenance procedures and manuals 

This just-in-time model ensures operators get the exact information they need right when they need it, without leaving the work area.

Key Benefits of Just-in-Time Training at the Work Area 

This approach to learning has proven to be more than just a convenience—it’s a strategic advantage. Some of the key benefits Milwaukee Tool realized through this initiative include: 

• Instant Access to Training and Support Materials 
  Scan to access video tutorials, machine startup instructions, and maintenance checklists, eliminating the need to search for manuals or wait for trainers. 
• Reducing Downtime with Immediate Training and Support 
  Minimize downtime by resolving issues faster with on-demand resources. 
• Customizable & Up-to-Date Content 
  Tailored training materials for each machine, ensuring relevance and current information. 
• Enhancing Safety 
  Direct links to safety checklists and protocols, helping reduce workplace accidents. 
• Data-Driven Insight 
  Track QR code scans to assess training usage and focus on areas needing improvement. 
• Empowering a Knowledgeable Workforce 
  Enable technicians to learn at their own pace, boosting confidence and skills. 
• Cost-Effective Training 
  Reduce training costs and eliminate the need for printed materials or ongoing training facilitators. 

Pilot Results: Less Downtime, Faster Onboarding 

Following the pilot, Milwaukee Tool saw measurable results. Operators used the QR codes to access information faster, reducing downtime and improving confidence on the floor. The program also helped create a culture of “self-help,” where employees felt empowered to solve problems on their own. 

The tool proved especially valuable for onboarding. Instead of overwhelming new hires with information upfront, the QR code system allowed them to learn in small, practical increments—right at the point of need. 

Looking Ahead: A Smarter Approach to Self-Learning 

Daniel Sellhausen, Manager of the Rapid Innovation Center at Milwaukee Tool, emphasized that companies must not only train workers upfront but also give them tools to continue learning as work evolves. This means making high-quality, accessible training materials available on the floor and designing them for real-world application. 

“Delivering consistent, on-demand access to knowledge is key,” said John Hindman, Director of Talent and Workforces Services at Tooling U-SME. “It ensures employees can perform effectively and adapt to changes, all while staying engaged in their development.” 

Both agree that avoiding poorly designed materials and investing in strong instructional design is critical. If you feed the system junk, it’s going to output junk. But if you take the time to do it right, self-learning can transform how we train and develop people. 

Smarter Training at the Machine 

Milwaukee Tool’s QR code training program shows how technology can make learning more accessible, relevant, and effective. By putting knowledge at the machine, they’ve empowered operators to learn in real-time, solve problems faster, and feel more confident in their work. 

With guidance from Tooling U-SME, they’ve created a scalable solution that not only reduces downtime but also strengthens the workforce. It’s a clear example of how thoughtful, just-in-time training can drive performance where it matters most—on the shop floor.  

For more details on this topic, check out the presentation recap from SME FUSION 2025.