AM/NS Calvert, one of the world’s most advanced steel finishing facilities, based in Mobile County, Alabama, produces 5.3 million tons of flat-rolled carbon steel annually. With 1,700 employees, the company serves industries ranging from automotive to HVAC. The location is a 50/50 joint venture between ArcelorMittal and Nippon Steel Corp. AM/NS Calvert is a key steel manufacturer for automotive, construction, and HVAC appliance industries in North America.
As a Senior Specialist, HDGL & Continuous Improvement at AM/NS Calvert, Tammy Lafferty oversees quality labs, environmental compliance, chemical management, and document control. A key issue she encountered was operator error, often due to outdated or ineffective work instructions. Traditional text-based documentation was not retaining knowledge effectively, leading to inconsistencies and operational inefficiencies.
Recognizing these challenges, the company’s Learning & Development team sought a better way to capture and transfer expert knowledge—leading them to DeepHow.
AM/NS Calvert adopted DeepHow to enhance training and standardize work instructions within the HDG lines. Tammy Lafferty quickly saw the potential of DeepHow’s Smart Videos to improve operational accuracy and efficiency.
A core team was initially assembled to lead the project, but as responsibilities shifted, Tammy Lafferty engaged frontline operators—many of whom had experience with videography and a passion for training. This grassroots approach accelerated adoption and created a sense of ownership among employees.
By analyzing operational data, the team identified their top five pain points—delays, rework, downtime, and safety concerns—and created DeepHow videos addressing these critical areas.
Since implementing DeepHow, AM/NS Calvert has achieved significant operational improvements. In addition to measurable improvements, the initiative uncovered inconsistencies between written procedures and actual workflows, prompting updates to outdated work instructions and improving compliance.
DeepHow’s customer success team played a key role in guiding AM/NS Calvert’s implementation, providing hands-on training and strategic planning support. The flexibility of DeepHow’s platform also allowed for continuous enhancements based on employee feedback.
AM/NS Calvert’s success with DeepHow highlights the power of AI-powered video work instructions in manufacturing. By transitioning from traditional text-based documentation to visual training, the company significantly improved knowledge retention, reduced delays, and enhanced safety.
For manufacturers looking to streamline training and operational efficiency, AM/NS Calvert’s experience underscores a simple truth when employees can see how a task is done, they learn faster, retain, and perform better.
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