Presented by: Mike Khavar Manager, Quality & Continuous Improvements

Committed to Value and QualityWarmelin Precision Products

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Supplier Excellence Alliance (SEA)Process Owner Forum

2.1.1 Job Skills & Cross-Training Certification Process

August 1, 2011

Presented by: Mike Khavar

Manager, Quality & Continuous Improvements

Certified Lean Expert & Master Black Belt

[email protected]


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Warmelin Precision Products is committed to providing the highest value to our customers. This is achieved by proactively investing into:

Continuous Improvement Efforts, Sharing of Cost Reductions, Implementation of Cellular Manufacturing Systems, and Total Quality

Management Philosophies.

Privately held organization

Established 1968

90+ employees

Annual sales $12.5 M

AS9100B, ISO9001-2008 Certified

ITAR / DDTC Certified & Compliant

SEA performing company since 2009 ( @ Phase 3 )

Company Vision:


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Warmelin Precision Products

Total Manufacturing Area: 25,000 SFIn the process of adding an additional 10,000 SF

Present Manufacturing Capabilities

Precision Milling

Precision Turning

ID/OD Grinding

Mechanical Assembly – Clean Room


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Our Simple Philosophy

PROVIDE VALUE FOR THE CUSTOMER

DELIVER QUALITY PRODUCTS ON TIME

APPLY SIMPLE MODELS TO COMPLEX SITUATIONS

INVEST IN THEFUTURE

INFRASTRUCTURE

CONTINUOUS IMPROVEMENT

CELLULAR MFG

RELATIONSHIPS


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Our Commitment to Relationships

Business of Developing and Fostering Relationships

" Customers

" Suppliers

" Employees

PROMOTES MUTUAL SUCCESS


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Our InfrastructureAGGRESSIVE TRAINING PROGRAMS

UTILIZING CONTROL SYSTEMS

SEEK & INVEST IN HIGHLY MOTIVATED PEOPLE

PROCESS DRIVEN ORGANIZATION

PROMOTING

COMMITMENT

ACCOUNTABILITY

QUALITY

FOCUS ON GOALS & RESULTS


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Certification LevelBronze OTD 90-94.9%, PPM <15,000Silver OTD 95-98.9%, PPM <10,000Gold OTD 99-100%, PPM <2,500

SEA Roadmap 2011


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2.1.1 Job Skills & Cross Training Certification Process

How is job skills training and certification accomplished at WPP? How does WPP ensure that processes selected are linked to key priorities for improvement? How is cross-training accomplished at WPP? How is the team of master trainers maintained and expanded at WPP? How is the training and cross-training program reviewed at WPP?


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WPP STRATEGIC PLAN FY2011

Vision StatementWe will increase revenue 20% by 2012 using lean processes company wide to become the preferred source for

Complex machined parts in the aerospace industry

Eliminate Escapes

Champion: Mike KhavarMetrics: Escapes, PPM

Actions

1.Establish Metric Definitions & Methodology 2.Analyze root cause and corrective actions for each escapes

Monthly Management Review on 2nd Tuesday of Each MonthChair: Doug Horton & Ron BohannonAttendee's: Mike Khavar, Dan Bohannon, Arturo Sanchez, Sherri Henkel, Nelia Avelino, Rue SegoviaAgenda to be distributed 5 business days prior to meeting. Agenda to include: Goal Reports by each Goal Champion including metrics, analysis & root cause, status against action plans. Performance Improvement Plan review. Customer Scorecard review. Communications Plan and Training Plan. And other actions as required.

STRATEGIC GOALS

On Time Delivery

Champion: Dan BohannonMetrics: Cust. OTD Chart

Actions

1. Analyze 10 latest each month using Root Cause Analysis, Trends, Actions

S.E.A Certification

Champion: Mike KhavarMetrics: S.E.A Metrics

Actions

1.Establish Action Plans 2.Employee Site Visits 3. Submit New Change

to Management Plan to S.E.A. For Comment


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2.1.1 Job Skills & Cross-Training Certification 2.1.1 Job Skills & Cross-Training Certification ProcessProcessName of the Process Job Skills & Cross-Training Certification Level of Maturity: 3 Date Achieved: 12/15/10

Process Champion Mike KhavarProcess Owner Mike KhavarPurpose of the Process

Describe what the business demands of the process and what the customer(s) expect from the process and quality requirements:Define certification criteriaTrain employeesCertify employees Ensure cross-training Maintain training and certification Records

Start of the Process Identification of required job skills certification End of the Process Employees certified in jobs skillsPerformance Metric Number of training hours per month / total labor hours

Number of certification issued per monthSupplier Name Specific InputMaster Trainer Create Training Curriculum

Certification Criteria Training Schedule Identification of Trainees (Cross-Training Matrix)

User Name Specific ResponsibilitiesMaster Trainers Training and certification of team membersCustomer Name Specific OutputEmployees Job Skills certified


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SEA-LES PROCESSESTrack Champions Process Owners (may be the same person as

the Champion)Owners

1. Leadership & Culture Ron Bohannon 1.1.1 Strategic Planning Ron

1.1.2 Leadership Communication Ron

1.1.3 Organizational Performance Review Ron

1.1.4 Continuous Improvement Management (usually same as Operational Excellence Champion)

Ron

1.1.5 Workforce Development Integration (usually same as Workforce Development Champion)

Ron

1.2.1 Supply Chain Integration Process Ron

1.3.1 New Product Startup Process Ron

2. Workforce Development Mike Khavar 2.1.1 Job Skills & Cross Training Certification

Mike

2.2.1 Continuous Improvement Process Mike

3. Operational Excellence Mike Khavar 3.1.1 Kaizen Process Dan

3.1.2 6S Visual Workplace Process Dan

3.1.3 Quick changeover/SMED Process Dan

3.2.1 Material Management Process Sherri

3.2.2 Production Planning Process Dan

3.2.3 Development Process Russ


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Preparation

Obtain:•Annual Workforce Development Plan created in 1.1.5• Job Skills Objectives (WI 7.7A)• Training Records Monthly MRM• Process Maturity Listing. • Strategic Plan

ChampionsProcess Owners Master Trainers

Collect Data

Compile data for review

Training Objectives Process Analysis Process Owner feedback

Feedback

• Collect Feedback.•Improve Process.

Reviews

• Review training, cross-training, and certification progress and feedback.• Review Master Trainer status.• Compare training objectives to training activities.• Review course outlines• Review process metrics and process owner feedback.• Review Strategic Plan goals

Monthly Management Review Meetings of Goals, Targets, Action Plans, Champion Reports and training updates.

2.1.1 Job Skills & Cross - Training Certification Process

Monthly All-Hands Employee Meetingsto review company performance,goal status, training progress and obtain employee feedback.

Training Plans


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All-Hands Employee Review Agenda

Strategic Objectives Performance Scorecard SEA Certification Progress Continuous Improvement Activities

(Kaizens, 6S) Training Activities Performance Incentive Plan (PIP) Employee Suggestion Box AS9100C conversion Progress Employee of the Month Award Open Q & A


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Short & Long Term GoalsNear-Term (12 mos.)• Achieve 94 OTD for all value streams• Reduce PPM on all value streams to < 3000• Continue lean implementation - achieve inventory turns of 5.4• Achieve a 20% growth• Achieve $220,000 Sales per employee• Achieve a quick ratio of 1.4

Medium-Term (12-24 mos.)• Achieve 95 OTD for all value streams• Reduce PPM on all value streams to < 2500• Continue lean implementation - achieve inventory turns of 5.5• Achieve a 20% growth• Achieve $223,000 Sales per employee• Achieve a quick ratio of 1.5

Long-Term (24+ mos.)• Achieve 96 OTD for all value streams• Reduce PPM on all value streams to < 2000• Continue lean implementation - achieve inventory turns of 5.6• Achieve a 20% growth• Achieve $225,000 Sales per employee• Achieve a quick ratio of 1.6


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WPP Employee Training menu curriculum

• MANUFACTURING SKILLS– Lathe CNC Machining operations skills– Mill CNC Machining operations skills– Grinding skills– Bench, Assembly & Deburr skills– M2M (Enterprise Resource Planning) system skills– Production Control planning skills– Shipping/Receiving operations skills– QA inspection/auditing skills– CMM programming skills– Safety related skills– General MFG practices skills


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• CONTINUOUS IMPROVEMENTS– Production Operations/Workflow/Process Improvements

– Quality Management Systems – AS9100 / ISO9001

– Certified Operator (CO) skills

– Change Leadership skills

– Six Sigma methodology skills

– SPC Process Capability skills

– Lean/Kaizen/6S’s skills

– Certified Internal Auditor (CIA) skills

– Total Productive Maintenance (TPM) skills

– SMED/OEE skills

– GD&T skills

– APQP/PCPX/PPAP skills


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• BUSINESS SKILLS

– Project Management skills

– Business Performance Skills (Accounting, Financial Controls, Inventory)

– Material Management skills


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Cross-Training Matrix


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Training Room


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M easure

E verything

T hat

R esults Customer Centric

I n

C ustomer

S atisfaction


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THE END

Thank You

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Presented by: Mike Khavar Manager, Quality & Continuous Improvements

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