Supplier Excellence Alliance 2.1.1 – Job Skills and Cross Training Certification Process 1/30/12...

Supplier Excellence Alliance2.1.1 – Job Skills and Cross Training

Certification Process

1/30/12Mary Porter, Human Resources Manager (Process Owner)

Guy Sykes, Training/SEA Administrator

© 2010 Vaupell Holdings, Inc. & Vaupell Molding & Tooling, Inc.

Who are we?

Privately held company established in 1947.Supplier of injection molded products and assemblies to

the aerospace, defense, medical and commercial markets. Capabilities include:o rapid prototyping o prototype and short run machining and casting o domestic and offshore tool design and build o custom fixtures and gauges o injection molding and contract manufacturing for small to large volume

production o Lightweight structural composite parts for aerospace and defense

applicationsFacilities in WA, MI, MA, NH, NY, and TX with

approximately 650 employees.o 65,000 sq ft of manufacturing area in the Seattle and Everett, WA

facilities with 365 employees.SEA certified company since 2010.


What We Believe

It begins with the New Employee Orientation following an employee importance theme to lay the groundwork for a

thinking workforce.From our Vision Statement:

o “…………….focusing on total customer satisfaction brought about by the empowerment of our employees.”

From our Mission Statement:o Developing the quality of our people.

A couple of our of our Core Values – oEmployee Focus - Employees are our most important assets. We recognize the importance of balance between work, family, and community.oTrust and respect – Demonstrating trust and respect for every individual will yield the dedication and commitment in achieving our mission.


Pre-employment testing Determination of requirements

o From strategic planning, customer inputs, cell/area requirements, etc.

Determination of need. Matching the employee to the skill sets.o What does the employee know?o What does the employee NEED to know?

Develop the training resourceso Internalo Externalo MT/SME

Conduct the training “Phased” mentoring Evaluating performance Document completion Recurring training/recertification Feedback and audits

Process flow - Developing the Employee

Annual Strategic Planning (SEA 1.1.1)Organizational Performance Review (SEA 1.1.3)Continuous Improvement Process (SEA 1.1.4 )New EmployeeNew PositionEmployee Performance ReviewCorrective and Preventative ActionNPI Process

New Employee

?

Needs Identified from Input Source(s)

YesNew Employee

Orientation

AdditionalTrainingNeeded?

Dept Manager or Process OwnerReview/Develop Requirements

No

Yes

Dept Manager or Process OwnerSelect Master

Trainer

TrainingCourse Available

& on Matrix?

Master Trainer Develops Training

Course Using16-Step SEA

Process

No

Training

A) Internal (Classroom or OJT)B) External ProviderParticipation Documented

Yes

Test & Certify

ResultsDocumented

HR to Recordon

Matrix and File

No

END

Job Skills & Cross TrainingCertification Process


Planning and expectations

1. Purposea. The purpose of this document is to define the training department, describe the training process and documentation, and identifying the internal and external training required by departments. Included are a rough timeline for accomplishment and budgeting request.

2. Reference DocumentsHW06-02-01, Training (atch 1)HW06-02-03, New Employee Orientation (atch 2)

3. Overviewa. Training will run under the premise that everyone needs training. It will be departmental and task specific in three parts. Departments are responsible for identifying specific training needs (atch 3, Departmental Assessments).b. Most training will be internally facilitated especially for skills and sessions deemed to be Vaupell core competencies. Leadership and communication training will be externally facilitated.c. The Training Department consists of one Training Administrator responsible for identifying training needs, developing training materials, conducting training, verifying effectiveness of training, and tracking training completion.

i. Each functional area will have Master Trainers and Subject Matter Experts responsible for training within their departments each determined by Supplier Excellence Alliance criteria and training. ii. This core group will meet once per month as a Training Department.

d. Document Training.i. Training to department or job specific sections of the Quality Manual (QMSM100).Departments are responsible for determining which QMS documents apply and for administering departmental training. This is knowledge level training for operations or skill level training for office tasks.


What’s new?

Monthly Training meetings. More frequently if warranted.o From strategic planningo From customer (changing?) requirements and

feedbacko Updated or new processes stemming from new

designs and new manufacturing practiceso From kaizen, VSM, and process improvementso Development of best practices (industry or internal)

How does your organization ensure that processes selected are linked to key priorities for improvement?


Tell me what you need!

Mold Press

Oper

Molding Material Handler

Molding Set-up/

Toolroom Tech

Molder/Supv

Mold ProcessTech

Molding Lead

Molding Auditor/ Trainer

Basic Computer Skills and the V-net XBasic Machining Equipment and Fixtures XBasic Safety, PPE, Haz Comm XDocumentation XDrill Press Set-up and Operation XHandheld Tools XHazardous Communication XIntroduction to 5S XIntroduction to Lean Manufacturing XIntroduction to TPM XJob Pack (AS07-05-03) XLabeler XLine Set-up and Clearance XReading Blueprints and Drawings XUsing Calibrated and Measuring Equipment XVisual Inspection (QS08-02-01) XFirst Part Buy-off for Molding (MW08-02-03) XForklift XMaterial Handling (MW07-05-07) XRegrinding materials (MW07-04-02) XVideojet Set-up and Operation XBasic Assembly Skills XBasic Sonic Welding (AS07-05-02) XCNC Router XEquipment and Fixture set-up XFilling Out Move Tickets (WW07-05-03) XPart Marking XPress set-up XSMED XTooling Configuration XProcess/Cycle Press - run set-up parts XScientific Injection Molding (off-site course) XPicking Work Orders XSupplier Excellence Alliance & Process Ownership X X XTraining the Trainer X X XBasic Root Cause/Corrective Actions X X XCommunicating with Diverse Groups X X XManaging Diverse Teams and Workgroups X X XLeadworker Effectiveness X X XUnderstanding 5S X X XLean Manufacturing and Applying Lean Techniques X X X

Prod Oper 1

Prod Oper 2

Prod Oper 3 Assy Lead Assy Supv

Basic Assembly Skills X

Basic Safety, PPE, Haz Comm X

Basic Sonic Welding X

Bonding and Adhesives X

Documentation X

Drill Press Set-up and Operation X

Filling Out Move Tickets (WW07-05-03) X

Handheld Tools X

Hazardous Communication X

Heat Staking X

Introduction to 5S X

Introduction to Lean Manufacturing X

Introduction to TPM X

Videojet Operation X

Visual Inspection (QS08-02-01) X

Sand and shell Room Operations X

Cleaning parts X

Part Marking X

Riveting X

Sublimation X

Basic Computer Skills and the V-net X

First Part Buy Off (AW08-02-02) X

Job Pack (AS07-05-03) X

Pad Printing Set-up and Operation X

Reading Blueprints and Drawings X

Using Calibrated and Measuring Equipment X

Videojet Set-up X

Fixture Set-up X

Equipment and Fixture set-up X

Line Set-up and Clearance X

Sonic Weld Set-up X

Supplier Excellence Alliance & Process Ownership X X

Training the Trainer X X

Communicating with Diverse Groups X X

Managing Diverse Teams and Workgroups X X

Leadworker Effectiveness X X

Understanding 5S X X

Lean Manufacturing and Applying Lean Techniques X X

Basic Root Cause/Corrective Actions X X


Intellectual tooling

Dual channelo Classroom with practical trainingo Demonstration

Cell or area coaching, facilitation, mentoringo Supervised hands-on work with product

Performance evaluationo Leads to unsupervised work with product

6 month process recertification on certain skills

How is job skill training and certification accomplished?


One part adhesive They consist of a single component that

hardens by temperature, humidity, or both combined with time when removed from their container and exposed to the environment.

• In use at Vaupell include: DC-3145/PR-1204 primer, RTV-102, Superglues (Loctite), 3M Industrial Adhesive 1870.

Two part adhesives. o They consist of a resin or base component that

has to be mixed with a catalyst in order to cure. Neither will harden until they are mixed together. The base is the adhesive. The catalyst is the hardener that when mixed with the base causes a chemical reaction that results in a cure.• Pre-measured (cartridges). In use at Vaupell

include: EC-3532, Uralane 5774, Uralane 5779, Hysol U-05FL, Hysol 608, DP-125, DP-190.

• “You” mix adhesives (kits). In use at Vaupell include: Proseal 870, Proseal 890, EC-3532, EC-2216 (both gray and translucent), Hysol EA-9330, PR-1776.

Documentation

9.1 BondingSection

Requirement-9.1.1 Equipment Requirements Y/N

Score

Are all safety requirements followed and proper equipment worn?

Can the operator properly handle a glue gun? Is the operator able to regulate the air pressure

as needed?

Requirement- 9.1.2 Application Requirements Y/N

Score

Is the bonding surface properly cleaned and prepped?

Does the operator apply a sufficient amount of adhesive to the bonding area?

Is the operator able to determine when the batch of adhesive should be replaced with a fresh amount?

Where used, are bonding fixtures kept clean and in proper working condition?

Has the adhesive been properly applied (fillet or no fillet) and cleaned where needed?

Where appropriate, is the bonding area properly clamped and the part stacked for curing?

Did the operator record lot number and expiration date (trace information) on the work instructions?

Actual Points Possible Points 10

Section 9.1 Total Score %

Training Program ChecklistBonding and Adhesives Proficiency

For scoring purposes, Y answer =1 point, N= 0 point. Employee must pass each section with a score of 80%

or better to pass Module.


How is the training and cross training program reviewed?

Positions:

4th Shift Transactions

Advanced Sonic

Welding

AP07-05-01, Assembly

Process Map, Rev E

AS07-05-02, Sonic Welding

SOP, Rev B

AS07-05-03, JOB PACK Standard

Work

AW07-04-01, Receipt and Handling of

Chemicals and Adhesives in

Assembly, Rev H.

AW07-05-01, Processing

Work Orders in Assembly,

Rev M

AW07-05-04, Maintenance

and Use of Production

Aids in Assembly, Rev

D.

AW07-05-06, WIP

Transactions for Assembly,

rev B

AW07-05-10, Assembly Tool and Equipment Maintenance,

Rev B

Accounts Payable/Receivable

Assembly Auditor X X X X X X X X X

Assembly Inspector X X X X X X X X

Assembly Lead X X X X X X X X X X

Assembly Manager X X X X X X X X X X

Assembly PO1 X X X X X X

Assembly PO2 X X X X X X X X

Assembly PO3 X X X X X X X X X

Assembly Supervisor X X X X X X X X X

Assembly Tech X X X X X X

Configuration Management X X X X

Controller X X X X

Cost Accounting Analyst X X X X X X

CSA X X X X X X X X

Customer Service Manager X X X X X X X X X

DCC X X X X X X


Where MT/SME come from.


Who’s driving the bus?

How is the team of master trainers maintained and expanded?


Other supporting programs

“Adopt an Engineer”o Daily two way interaction and training between “the

technical” and “the floor” based on the schedule and not as reaction to a specific issue.

Partnership with North Seattle Community Collegeo Simplification of written build documentation.o Job specific and company terminology based ESL classes.

Daily team trainingo Informal with required membership and attendance.o “One minute manager” stuff.o No specific agenda – very fluid.


The final act!


Questions and Input

Supplier Excellence Alliance 2.1.1 – Job Skills and Cross Training Certification Process 1/30/12...

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