The automotive manufacturing industry is undergoing a significant transformation, shifting from hardware-centric automation to software-driven intelligence. This change has created a gap between what engineers learn and what they encounter on the factory floor. To address this issue, Toyota Motor Manufacturing UK has launched a new training approach at its Burnaston plant in partnership with Rockwell Automation. The program combines classroom learning with hands-on experience, using current-generation Rockwell hardware and software to ensure that apprentices learn the skills required for modern production.
The training model is designed to bridge the gap between theoretical knowledge and practical application. Apprentices spend two years building technical and behavioral competencies in a classroom environment, followed by two years applying those skills on the shop floor. The program also addresses the aging maintenance workforce by building a long-term talent pipeline and extending outreach into local schools to foster early interest in engineering and STEM careers.
Stephen Heirene, Industry Consultant for Transport and Future Mobility at Rockwell Automation, emphasizes the importance of training that reflects real-world applications. He notes that legacy equipment is no longer sufficient, and that modern production environments require engineers who understand not just machinery but networks, databases, and analytics platforms. Rockwell’s approach centers on outcomes rather than products, aligning with customers’ goals and selecting the appropriate technologies to support those goals.
The company’s training infrastructure includes classroom training, virtual modules, and portable training rigs that ensure hands-on learning. The emphasis is on building a comprehensive understanding of manufacturing operations, including the digital thread that connects design, production, and maintenance systems. Networking competency is emerging as a critical skill for modern manufacturing engineers, who must be able to troubleshoot communication failures, understand data flow, and secure industrial networks against cyber threats.
Rockwell’s support for manufacturers includes helping them navigate the transition from legacy systems to modern digital architectures. The company provides technologies across the Purdue model, from shopfloor sensing to cybersecurity, data analytics, and AI. Established manufacturers face the added complexity of maintaining existing systems while implementing new ones, requiring training that addresses both legacy equipment knowledge and contemporary digital skills.
The question of what happens next is crucial, as automotive manufacturing continues to evolve towards electrification and autonomous systems. Training systems must evolve to keep pace with current technology and anticipate future requirements, as engineers entering the workforce today will spend their careers navigating constant technological change. Rockwell’s position at the convergence of these challenges enables the company to help manufacturers navigate the transition and build a workforce that is equipped to meet the demands of the future.
The automotive industry’s evolution requires a workforce that is agile, adaptable, and able to learn new systems quickly. The ability to learn and apply new skills is becoming increasingly important, and manufacturers must prioritize training and upskilling initiatives to remain competitive. By supporting both established manufacturers and start-ups, Rockwell is helping to drive the transformation of the automotive industry and ensure that the workforce is equipped to meet the challenges of the future.
In conclusion, the partnership between Toyota and Rockwell Automation is an example of how industry leaders are addressing the skills gap in automotive manufacturing. The training model developed at the Burnaston plant is a comprehensive approach that combines classroom learning with hands-on experience, using current-generation hardware and software. As the industry continues to evolve, it is essential that training systems keep pace with current technology and anticipate future requirements, ensuring that engineers are equipped to navigate the complex and rapidly changing landscape of automotive manufacturing.