New Operator & Multi Skill Training

8/2/2019 New Operator & Multi Skill Training

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NEW OPERATOR AND

MULTI-SKILL TRAINING PLAN

Aluminium Alloy Industries Sdn Bhd

Prepared by : P.SashendranLPS Kaizen Center


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1. How to be a good Trainer?

Process Knowledge

P

atience

Pe

rsistence

Pos

itiveMind

Skilled Operator

Good Trainer

MasterThe4P


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2. Supervisor's Role in Training

Create OperatorTraining Plan

Train Operators

Check TrainingEffectiveness

Re-train forNon-Compliance


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3.1 New Operator Training Plan - Step1

H R T r a i n e r V e r i f i e d

O p e r a t o r N a m e : D e p t / S h i f t :

S t a t u s : C o n t r a c t / F o r e i g n / L o c a lT r a i n i n g A r e a :

D a t e J o i n e d : E x e c u t i v eS u p e r v i s o rE n g i n e e r / E x e c

N oP l a n I t e m P I C D a y 1 ~ 6D a y 7 ~ 1 2D a y 1 3 ~ 1 8D a y 1 9 ~ 2 4D a yS t a

( 1 )C o m p a n y R u l e s H R 1

( 2 )S a f e t y & P P E R u l e sS u p e r v i s o r 1

( 3 )3 S T r a i n i n g S u p e r v i s o r 1 ~ 3

( 4 )O J T T r a i n i n g S u p e r v i s o r

- S t a n d a r d i z e d W o r k S u p e r v i s o r 2 ~ 1 8

- S O P S u p e r v i s o r 2 ~ 1 8

- I n s p e c t i o n S t a n d a r dS u p e r v i s o r 2 ~ 1 8

- Q u a l i t y B u y - O f fS u p e r v i s o r 2 ~ 1 8

( 5 )N o n C o n f o r m a n c e P a r t H a n d l i n gS u p e r v i s o r 3 ~ 4

( 6 )O u t p u t S h e e t & C h e c k s h e e tS u p e r v i s o r 5 ~ 6

( 7 )W o r k O b s e r v a t i o nS u p e r v i s o r 1 9

( 8 )S k i l l E v a l u a t i o n S u p e r v i s o r 2 0

( 9 )T r a i n i n g P l a n f o r S k i l l U pS u p e r v i s o r 2 1

H O D

A p p r o v

STEP 1 : HR will fill up

Operator name, Status,Date joined and whichDept and shift the

Operator is assigned to.Inform new operator of

Company Rules. Sign offform and hand over theform and operator to therespective supervisor


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- S O P S u p e r v i s o r 2 ~ 1 8








H O D

A p p r o v

STEP 2 : Safety & PPE rules- Supervisors will show the employes the typeof PPE used at their work area.

- Train the operators how to use the PPE properly- Train the operators on the safety aspects of the

work area and machines.


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- S O P S u p e r v i s o r 2 ~ 1 8








H O D

A p p r o v

STEP 3 : 3S Training- Fixed locations of all materials, tools, PPE, etc

- Where to dispose unwanted materials- How to arrange materials and tools- Cleaning of work area and machines


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- S O P S u p e r v i s o r 2 ~ 1 8








H O D

A p p r o vSTEP 4 : OJT Training- Standardized Work, SOP, Inspection Standard &Quality Buy-off training

- Test operators daily on what was learned- Update status on the 7, 13, 19th day of training

What is standardized work? What is SOP?What is the difference between both?


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- S O P S u p e r v i s o r 2 ~ 1 8








H O D

A p p r o vSTEP 5 : Non Conformance Part Handling- Train operators where to place reject and repair parts- Train operators how to mark these parts- Train operators to report NC part issues to the

Supervisor at all times


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- S O P S u p e r v i s o r 2 ~ 1 8








H O D

A p p r o vSTEP 6 : Output sheet and checksheet- Train operators on how to fill up check sheet and

output sheet.- Stress on real timereporting.- Check on how they are filling up the sheets. If theyMake mistakes, re-train until they fully understand.



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3.7 Operator Work Observation

S L . N O R e s u l t a f t e r r e - t r a i

1

2

3

4

5

6

7

8

9

1 0

1 1

1 2

1 3

C o m m e n t s ( H O D ) r e l a t e d d e p a r t m e n t

D a t e :

N O T E

1

2

3 I f , R e t r a i n a n d r e - o b s e r v e s t i l l f a i l , o p e r a t o r h a s t o s t o p p r o c e s s i m m e d i a t e l y a n d r

I f , t h e o p e r a t o r f o l l o w s a l l t h e a b o v e m e n t i o e d c r i t e r i a :C o n g r a t u l a t e h i m

I f , t h e o p e r a t o r f a i l s o n a n y o n e o f t h e a b o v e m e n t i o n e d c r i t e r i a :R e t r a i n a n d r e - o b s e r v e i m m e d i a t e

C O M P L E T E T A S K I N T I M E ?

S i g n a t u r e o f t h e D e p a r t m

F O L L O W I N G 3 S ?

D O I N G V I S U A L I N S P E C T I O N ?

I N S P E C T I O N A S P E R L I M I T S A M P L E ?

S A F E T Y W O R K I N S T R U C T I O N F O L L O W E

P A R T H A N D L I N G A S P E R P R O C E D U R E ?

W O R K I N G A S P E R W O R K S T A N D A R D ?

M A I N T A I N D I S C I P L I N E I N W O R K P L A C E ?

N C H A N D L I N G P R O C E D U R E F O L L O W E D

A B N O R M A L S I T U A T I O N F O L L O W E D ?

W H E T H E R H E F O L L O W E D R E A C T I O N P L A

Y E S ( O R ) N

S T A R T U P P R O C E D U R E F O L L O W E D ?

O B S E R V E R :

F O L L O W I N G S O P ?

D A T E O F O B S E R V A T :

T O P I C

S E C T I O N / S H I F T :

A L U M I N I U M A L L O Y I N D U S T R I E S

O P E R A T O R W O R K O B S E R V A T I O N

O P E R A T O R N A M E :

How to do work observation ?Why is work observation important?


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- S O P S u p e r v i s o r 2 ~ 1 8








H O D

A p p r o v

STEP 7 : Work Observation- Fill up operator work observation report and identifyAreas where re-training is required.


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3.9 Skill Evaluation for All Operators

M o n t h l y H a l f Y e a r l y 1

Q u a t e r l y Y e a r l y 2

3

4

2 . 0 A s s e s s m e n t R e c o r d

M a i n P r o c e s s : A W C A S T I N G

N o N a m e Y e a r o f J o i n i n g

1

2

3

4

5

M a c h i n e M

O p e r a t iF i l t e r P l A i r B l o G a t i n g R P a r t I n s p

D a t e :

C h e c

O v e r a l l J u dP a r t I d e n t i f D i e C o a t

1 . 0 T r a i n i n g E v a l u a t i o n / C o m p e t e n c y E v a

D a t e : D a t e :

J u l y -

D i e C l e

E v e r y P r o j e c t / A t

D i e S e t

T y p e O f P r o c e s s e s

O c t -

A p p r o A s s e s

Q u a r t e r ()J a n -

A p r -

o n j

t r a it o p e r f o r t

g u i d a n c e

A b l e t o p e

i n d e p e n d t ta s p e c t o n t t

q u a l i t y s a t t

k n o w l e d g t

a s p e c t o f t

t r a i n n e w

What is the difference between our current skill chartand the one shown here? Currently, How do we judgeThe operator skill level?


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3.9.1 Skill Evaluation - Sample

2 . 0 A s s e s s m e n t R e c o r d

S e c t i o n : W a s h i n g & L e a k T e s t i n g

N o N a m e Y e a r o f J o i n i n g

1 1 5 . 0 3 . 1 9 9 5

2 1 6 . 0 6 . 2 0 0 6

3 1 4 . 0 6 . 2 0 0 7

4 1 4 . 0 6 . 2 0 0 7

5 C O N T R A C T

O v e r a l l J u d gW a t e r L e a kU s e o f M e a s u W a s h i n g F l u s h i n g M

T y p e O f P r o c e s s e s

S H A R I F

S H W E

R A J K

L I L A

I M R A N H

1 0 0 1 0 0 1 0 0 1 0 0 1 0 0

1 0 0 1 0 0 1 0 0 1 0 0 1 0 0

1 0 0 1 0 0 1 0 0 1 0 0 1 0 0

1 0 0 1 0 0 1 0 01 0 0

1 0 0

5 0 % 5 0 % 5 0 % 5 0 % 5 0 %


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3.9.1 Skill Assessment - Sample

3 . 0 A s s e s s m e n t R e p o r t

S U P E R V I S O R

C h e c k e A s s e s sA p p r o v

D a t e : 3 0 . 1D a t e : 3 0 . 1D a t e : 3 0 . 1

N a m e O v e r a l l J u d g e m e n t R e m a r k s

S e c t i o n :W a s h i n g & L e a k T e s t i n g

A s s e s s m e n t :

- K n o w l e d g e o f a l l t h e a s p e c t o f w o r k a n d a b l e

o n j o

t r a i n

t o p e r f o r m

g u i d a n c e f

A b l e t o p e r f

i n d e p e n d e n

a s p e c t o n p r

q u a l i t y s a f e

k n o w l e d g e

a s p e c t o f w

a b l e t o t r a i

w o r k e r s

S H A R I F


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( 2 )S a f e t y & P P E R u l e sS u p e r v i s o r 1( 3 )3 S T r a i n i n g S u p e r v i s o r 1 ~ 3



- S O P S u p e r v i s o r 2 ~ 1 8








H O D

A p p r o v

STEP 8 : Skill Evaluation- Fill up skill chart and assessment form- Identify operator's low skill areas for skill uptraining


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3.11. Skill Improvement Plan

(1) Purpose is to upgrade operator skill level at least to75%. Meaning the operator can do the job by himselfwithout assistance from the supervisor.

(2) An action plan to improve operators's skill level

(3) 3 months planning (quarterly plan)

(4) Refer to attached skill evaluation form and sample.


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( 2 )S a f e t y & P P E R u l e sS u p e r v i s o r 1( 3 )3 S T r a i n i n g S u p e r v i s o r 1 ~ 3



- S O P S u p e r v i s o r 2 ~ 1 8








H O D

A p p r o vSTEP 9 : Training plan for Skill Up- Fill up skill improvement plan- Submit New Operator Introduction Training Plan,Skill chart & assesment and Skill Improvement PlanTo Engineer/Exec for verification and HOD for approval

- Send a copy to HR dept after approval

How does engineer/exec and HOD verify and approve?


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3.12. Sample of filled up form


O p e r a t o r N a m e : B a h a d u rD e p t / S h i f t : C a s t i n g B

S t a t u s : C o n t r a c t / F o r e i g n / L o c a lT r a i n i n g A r e a : A l l o y W h e e l C a s t i n gT e e K a d i r I z w a n

D a t e J o i n e d :1 / 6 / 2 0 1 0 E x e c u t i v eS u p e r v i s o rE n g i n e e r / E x e c

N o P l a n I t e m P I C D a y 1 ~ 6D a y 7 ~ 1 2D a y 1 3 ~ 1 8D a y 1 9 ~ 2 4D a y S t a t


( 2 )S a f e t y & P P E R u l e s S u p e r v i s o r 1



- S t a n d a r d i z e d W o r kS u p e r v i s o r 2 ~ 1 8

- S O P S u p e r v i s o r 2 ~ 1 8


- Q u a l i t y B u y - O f f S u p e r v i s o r 2 ~ 1 8


( 6 ) O u t p u t S h e e t & C h e c k s h e e tS u p e r v i s o r 5 ~ 6

( 7 )W o r k O b s e r v a t i o n S u p e r v i s o r 1 9



A p p r o v e

H O D

S a s h e


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4. Operator Multi-Skill Training Plan

(1) Purpose is to have operators capable to do differentprocesses for the smooth flow of operations.Reduction in downtime due to operator absence,resignation, contract term over, etc.

(2) For operators who have achieved min 75% skilllevel in their current process

(3) Refer to Multi skill training plan form and sample

Current Process

(Alloy Wheel Casting)Skill Level 75%

Plan for Multi-SkillTraining in

(Engineering Casting)


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O P E R A T O R M U L T I S K I L L T R A I N I N G P L A N

T r a i n e r V e r i f i e d



D a t e J o i n e d : S t a r t T r a i n i n g D a t e : S u p e r v i s o rE n g i n e e r / E x e c

N o P l a n I t e m P I C D a y 1 ~ 6D a y 7 ~ 1 2D a y 1 3 ~ 1 8D a y 1 9 ~ 2 4D a y S t a t

( 1 ) S a f e t y & P P E R u l e s S u p e r v i s o r 1

( 2 ) 3 S T r a i n i n g S u p e r v i s o r 1 ~ 3( 3 ) O J T T r a i n i n g S u p e r v i s o r


- S O P S u p e r v i s o r 2 ~ 1 8

- I n s p e c t i o n S t a n d a r d S u p e r v i s o r 2 ~ 1 8

- Q u a l i t y B u y - O f f S u p e r v i s o r 2 ~ 1 8

( 4 ) N o n C o n f o r m a n c e P a r t H a n d l i n gS u p e r v i s o r 3 ~ 4( 5 ) O u t p u t S h e e t & C h e c k s h e e tS u p e r v i s o r 5 ~ 6

( 6 ) W o r k O b s e r v a t i o n S u p e r v i s o r 1 9

( 7 ) S k i l l E v a l u a t i o n S u p e r v i s o r 2 0

( 8 ) T r a i n i n g P l a n f o r S k i l l U pS u p e r v i s o r 2 1

A p p r o v e

H O D

Form is similar to new operator introduction plan.HR is not the initiator of this form.Supervisors will initiate this form

4.1 Multi-Skill Training Plan Form

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