Pre-Conference Luncheon - ncpn.info · Pre-Conference Luncheon Oct 25, 2017 My Safety Commitment...
Transcript of Pre-Conference Luncheon - ncpn.info · Pre-Conference Luncheon Oct 25, 2017 My Safety Commitment...
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National Career Pathways Network Pre-Conference Luncheon Oct 25, 2017
My Safety Commitment “I will strengthen the Toyota Bodine safety culture by applying the principles of knowledge, mind, and action.”
Manufacturing Talent Wes Woods, VP Toyota-Bodine Aluminum
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Wes Woods
Vice President, Toyota Bodine [[email protected]]
Experience: 34yrs Automotive Manufacturing (Powertrain)
Career: Production Floor Team Member, Engineer, Supervisor, Manager, GM, VP
Academic Outreach - Elementary to Post Secondary
Personal Introduction
- Support High School STEM Academies - Robotics and related STEM programs K-12 - National Visiting Committee Member for CARCAM (carcam.org) Alabama Regional Technical College Workforce Development - Have lectured at colleges in Southeast US
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Presentation Outline 3
1.Toyota Bodine Company Overview
2.The Need for Skilled Manufacturing Technicians A. The Skills Gap B. The Gap Between Students and Manufacturing Jobs C. The Creation of Advanced Mfg Technician (AMT) D.Missouri FAME and Statistics E. Reflections, Improvements, Call for Action
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TITLE
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Parts Mfg
Wheels
Cars, Engines, Engineering HQ
Cars, SUVs
Castings - Blocks - Heads - Transmission
Engines Transmissions Vans
SUVs
Engines Trucks
Trucks
Cars
Toyota Manufacturing in North America
Corp. HQ
Design HQ
- 10 Mfg Locations in U.S. (14 in N.A) - 1.4M Vehicles Produced in U.S. (2016) - $23.4B Direct Investment in U.S. - 136,000 Dedicated U.S. Employees - $921M in Total U.S. Donations
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Toyota Bodine Plants and Customers
Troy, MO
Jackson, TN
Kentucky Engines,
West Virginia - Transmissions - Engines
Alabama Engines
STL, MO
135 Employees
294 Employees
852 Employees
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- 2016 Marks 26 Years with Toyota
Bodine Aluminum History/Timeline
- Bodine Celebrated 100th Anniversary in 2012
Bodine Pattern
Shop Founded
1912
Toyota Purchased
Bodine
1990
Troy, MO Plant Began
Production
1993 2005
Tennesse Plant Began
Production
100 Year Anniversary
2012 2016
One Toyota
N.A. Reborn
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• Tundra • Sequoia
• Camry • Rav4 • Corolla
• Avalon • Tacoma • Sienna • Highlander • Lexus RX & ES
Bodine Produces Aluminum Castings
Head Castings
Block Castings
Transmission Castings
L4 Engine
V6 Engine
V8 Engine
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6 million castings per year.
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STEM Education
NPLD
Food Bank
Vehicle Donations
Playground Donations
ADA Accessibility at State Park Diversity Education
Support Local Agencies
Computer Donations
Community Betterment – Troy and St.Louis
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Solar Lights
Reducing Resource Consumption Tree and Foliage Planting
1. Reduce 2. Reuse 3. Recycle
We Value Our Environment
We are a Zero Landfill Company Environmental Month Activities
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What If I Told You? 10
We have a career pathway for Your Child that…
Raise Your Hand - If you would consider this opportunity for your child.
1. Has a Base Pay of $40K - $60K per Year.
2. Has Overtime Pay, Medical Benefits, 401K, PTO, etc.
3. Has Growth & Advancement Opportunities
4. Only Requires a 2yr Degree
7. The Graduation Rate > 80%
8. The Employment Rate > 90%
..IN A MANUFACTURING CAREER.
5. Provides Practical Job Experience while in School
Can Graduate with Little or No Debt
6. Pays a Salary as Part of the Program
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Clarify The Need – Manufacturing Technicians
Mfg Needs Capable Multi-Skilled Maintenance Technicians
1) Strong Technical Ability Industrial Maintenance from Technical or Community College - Electrical Repair - Motor Controls - PLC - Machine Tool - Fabrication - Welding - Mechanical Repair - Robotics - Other Automation
2) Soft Skills Proficiency - Effective Communication - Teamwork - Problem Solver (incl. root cause analysis) - Critical Thinker - Punctual
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84%
0% 0%
Executives who agree there is a talent shortage in U.S. mfg.
82% Executives believe the skills gap will negatively impact their ability to meet customer demand
78% 69% 62% 48%
Will Implement new technologies
Are providing effective customer service
Developing new products
Expanding internationally
Problem - There’s a National Skills Gap
Manufacturing Largest Skill Gap of any Workforce Sector - Health Care - Retail - Energy - Construction - etc.
How Do We Close this Skills Gap?
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Student
Manufacturing Jobs
Engineers & Other 4yr
Degree Professions
Teachers & Parents
Universities
Maintenance Technicians
Must Create an Effective Pathway for Students 13
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What Employers Need Today
What Employers Historically Receive
Define the Job and the Technical Gap to Close
Silo’d Skilled Maintenance - Electricians - Mechanics - Welders - Machinists - Tool Makers - Programmers - Etc
Multi Function Technician (and More)
Key Change Points
1. Global Competition - Cost - Quality - Value
2. Shareholder Pressures - Accomplish more with the same resources
3. Advanced Technologies - Machines PLC, Computer Automation - Materials Plastics, Resins Other Composits
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1. Five Semesters Five Areas of Study
The “Standardized Degree” for Mfg (AMT)
General Education - Language - Science - Math - History
Mfg. Core Exercises
Professional Behavior
Job Experience
- Safety - Organization - Problem Solving - Lean Mfg.
- Electricity - Mechanics - Robotics - Fabrication
Technical Education
- Teamwork - Communication - Work Culture
- On-Job Training - Job Mentoring
2. Create Partnership State Technical College of Missouri
Develop Curriculum and Classroom. (Yokoten)
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The “New Model School” for Mfg (AMT) We’ve Developed a Place of Learning that
Looks and Feels Much Like a Place of Work
More Realistic Looks and Feels like a factory
Mfg Simulator For learning how to troubleshoot problems
Additional Learning - Safety - 5S - TPS
Process Learning - Structure - Sequence - Right first time
Org Structure - Electricity - Fluid Power - Mechanical - Fabrication, etc
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Wor
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M Tu W Th F
8-10
hrs
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SCHO
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SCHO
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Program Work (1-2 hrs) 2-
4 hr
s Homework and Study 2-4 Hrs
The “New Model Regimen” for Learning (AMT) A Realistic Work - Study Experience. “Every Minute Counts”
40 Hour Work / Study Week
8-10
Hrs
5 Continuous Semesters
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The Student Earns $20K/yr While in School
Sem
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Sem
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Sem
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Sem
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GRAD
UATI
ON
16 Weeks
Fall 2015
Semester
Spring 2016
Semester
16 Weeks
Summer 2016
Semester
16 Weeks
Fall 2016
Semester
16 Weeks
Spring 2017
Semester
16 Weeks
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The Next Step for AMT MO FAME
- HQ: State Tech. College - 3rd Year in Program - 8 Industry Partners - 29 Students (total) - 9 Graduates to Date - 89% Graduation Rate - 89% Employment Rate
Statistics
Created a Collaboration with Other Local Manufacturers
8 Industry Partners
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1 K-12
2 College Tech Partners
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Work & Learning Readiness
Industry Best
Globally competitive achievement level
AMT
The Solution Is Fully Developed 19
Nationally - 16 Operations - 9 States - Over 160 FAME Companies
Work Preparation
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Student
Universities Teachers &
Parents
The Gap to Manufacturing Jobs is Closed
Colleges + Industry
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Manufacturing Jobs
Engineers & Other 4yr
Degree Professions
Technical Colleges
Other Tech Schools
Teachers, Parents, Industry
Maintenance Technicians
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Meet the New Generation Skilled Technician Totally Multi-Skilled - Electrical / Fluid / Mechanical / etc
Strong Math – Upper 1/3 Nationally
Fast Technical Learner - Can Learn, apply, improve, learn again
Uses and Learns with Digital Media
Strong Problem Solver - Can fully explain problem solving and methods
Effective Communicator - Group and 1-on-1. High quality writing skill.
Natural Team Worker - Prefers working as part of a team.
Prepared to Move to Next Level - Has Assoc. Degree & Req’d Company Training
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Not yet a Success Story – “Need Improvement”
We’ve Almost Completed the First PDCA Cycle
PLAN:
DO:
CHECK:
ACT:
Although mostly good, we’ve recognized opportunities to improve
We’ve implemented the Plan
We recognized a problem and made a plan.
We’ve Checked the Results.
Together, let’s take action and repeat the PDCA Cycle again.
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Key Objective – Strengthen the Connections
1. Not Enough FAME Applicants - Improve the perception of manufacturing. - Recruit students and parents
2. Not Enough Diversity - Deliberately Recruit Females and People of Color
3. Not Achieving the Main Goals - Clarify Recruiting Roles (high school, technical college, industry partners) - Increase our passion to recruit…and see it through to employment
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Diego Rivera – Detroit Institute of Arts
Kaizen – Improve The Perception of Mfg
Miserable Environment
Manual, Strenuous
Work
Crowded Conditions
- Unsafe - Dirty - High Overtime - Uncaring Leaders - Low Pay & Benefits - Frequent Layoffs
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< 20% of students said that their Parents or School Leaders encouraged them to pursue a career in manufacturing.
Early Manufacturing
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Kaizen – Strengthen Recruiting Methods
Hourly Annual
Mean Wage $22.11 $46,000 + Overtime
90% of Top Wage $31.84 $66,000 + Overtime
** Pay Stats (Bureau of Labor and Statistics May 2016)
Other Benefits 1. Overtime and incentive pay 2. Medical, Dental, Eye Care 3. Paid Holidays & Vacations
Reach Students and Parents with a Targeted Message 1) Students and Teachers visit local factories Learn & Teach Mfg
2) Deliberately educate students and Parents regarding the great career, pay, and benefits with manufacturing companies
3) Manufacturers are ready to support (not lead). Lack connections.
Problem Solving Bright, Clean, Safe Environment
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Kaizen – Deliberately Recruit Diversity
1. Recruiting POC and female technicians is challenging.
2. We have many STEM partnerships. Must consciously connect with under-represented groups.
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Kaizen - Point STEM Students Toward Mfg Jobs
Ben Harley
A Tale of 2 Wayward High School Students
Saturation with STEM in Middle / High School….
1. Is not enough by itself. Students need practical guidance. - Based on individual circumstances - Must see it through to employment 2. Cannot be sustained. Teachers can burn-out quickly.
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End
MOFAME First Graduating Class 28