How Kenvue built safety competency across nearly 100 people and found what was not visible before.

~100 People trained through the Competency Pathway
$500K Estimated cost avoided from a single finding
2024–2025 Program rollout

The client

Kenvue upskilled nearly 100 EHS professionals and operational leaders through the Learning from Normal Work Competency Pathway and avoided an estimated $500,000 from a single finding.

Kenvue is a global consumer health company with brands including Tylenol, Listerine, Band-Aid, and Neutrogena. Formed as an independent company from Johnson and Johnson in 2023, Kenvue operates across dozens of manufacturing and business sites worldwide.

The challenge

Kenvue's EHS leadership recognized that their traditional approach to safety was not enough to surface the kinds of problems that lead to costly mistakes and serious incidents. Workers were following procedures as they understood them, but gaps in those procedures, and in people's understanding of them, were going unnoticed.

They needed a capability-building program that would give their EHS professionals and operational leaders a different way of looking at work: one grounded in human and organizational performance, cognitive psychology, and systems thinking.

The program

Kenvue selected the Learning from Normal Work Competency Pathway, designed and delivered by Psychology Applied. The program was rolled out across 2024 and 2025, with nearly 100 participants completing the pathway.

The pathway covers multiple disciplines, including human factors, engineering psychology, resilience engineering, cognitive psychology, and systems thinking. Rather than theoretical overview, the program is structured around practical application: participants learn tools they can use on site, in real work, immediately.

The structure of the learning process led to better retention and confidence building. I found it easy to apply the concepts I learned in both safety-related and non-safety-related situations, making the training highly practical. The pathway sharpened my ability to spot error traps in processes, leading to more critical thinking and improved process design.
Brian Lubbert, Head of EHS North America, Kenvue

Two findings that show what competency-based training changes

Finding 1

The rebranding that nearly went wrong

Kenvue was in the middle of a major rebranding effort, transitioning from the former J&J visual identity to the new Kenvue brand across all business sites. At one site, the paint color being applied was not the exact specification but a close match. Workers were operating on a "close enough is good enough" basis. This was not deliberate non-compliance. The work instruction lacked the specific shade reference.

A Competency Pathway participant used the procedure review tool and found that the gap between the instruction and the required outcome was invisible until someone looked at the work through this lens.

The correct specification was provided before the error spread to additional sites. Kenvue avoided an estimated $500,000 in repainting costs and brand inconsistency across its facilities.

Finding 2

The fall protection rule nobody was breaking

During a construction project, an EHS advisor noticed a worker standing near a parapet wall without fall protection. The worker was not in compliance with local rules, but he believed he was. He had measured the combined vertical and horizontal distances and concluded, based on his understanding of the standard, that fall protection was not required.

Instead of enforcing compliance and moving on, the advisor used principles from the Competency Pathway and engaged the worker in conversation to understand how he had arrived at his interpretation. This revealed a systemic gap: if one worker held this understanding, others likely did too.

The misunderstanding was corrected without conflict. More importantly, the approach surfaced a gap in how the rule was being understood across the site, something a traditional compliance check would have missed entirely.

Why this matters

Both findings share the same pattern. Workers were doing what they believed was right. The gap between the procedure and the actual work was invisible to normal oversight. A trained person using a specific method made the gap visible before it became an incident or a costly problem.

This is what competency-based training changes. It does not replace the management system. It gives people the ability to see what the management system cannot see on its own.

Client snapshot

Organization
Kenvue
Industry
Consumer health / pharmaceuticals
Scope
~100 participants across the Competency Pathway
Program
Learning from Normal Work Competency Pathway (2024–2025)
Key outcome
$500K estimated cost avoided, systemic fall protection gap identified

Want to talk through what a similar program could look like for your organization?