Training Proposal for McWane, Inc. 17-0661 Page 1 of 5 TRAINING PROPOSAL FOR McWane, Inc. 17-0661 Panel Meeting Date: 06/23/2017 Regional Office: Bay Area Regional Office Analyst Name: Molinar, Luke Type of Proposal: Single Employer Contract (SE) Funding Source: Out-of-State Competition (OSC) FUNDING OVERVIEW Provided here is a summary of the funding for the proposed Training Project. TOTAL ETP FUNDING: $194,326.00 Program & Admin Cost Support Cost Substantial Contribution Total In-Kind $194,326.00 N/A N/A $250,000.00 APPLICANT PROFILE Company Summary McWane, Inc. (McWane) produces ductile iron products including pipe, valves, hydrants, fittings and plumbing products. Industry Sector(s) Manufacturing Priority Industry Yes No. of Employees (Applicant) State: 418 US: 4,671 World Wide: 4,671 Turnover Rate (Applicant) 8.40% Repeat Contractor No High Unemployment Area No Unions Glass, Molders, Pottery, Plastics and Allied Workers International Union Local 164-B
Transcript
Training Proposal for McWane, Inc. 17-0661 Page 1 of 5
TRAINING PROPOSAL FOR
McWane, Inc.
17-0661
Panel Meeting Date: 06/23/2017
Regional Office: Bay Area Regional Office
Analyst Name: Molinar, Luke
Type of Proposal: Single Employer Contract (SE)
Funding Source: Out-of-State Competition (OSC)
FUNDING OVERVIEW
Provided here is a summary of the funding for the proposed Training Project.
TOTAL ETP FUNDING: $194,326.00
Program & Admin Cost Support Cost Substantial Contribution Total In-Kind
$194,326.00 N/A N/A $250,000.00
APPLICANT PROFILE
Company Summary McWane, Inc. (McWane) produces ductile iron products including pipe, valves,
hydrants, fittings and plumbing products.
Industry Sector(s) Manufacturing
Priority Industry Yes
No. of Employees (Applicant) State: 418 US: 4,671 World Wide: 4,671
Turnover Rate (Applicant) 8.40%
Repeat Contractor No
High Unemployment Area No
Unions
Glass, Molders, Pottery, Plastics and Allied Workers
International Union Local 164-B
Training Proposal for McWane, Inc. 17-0661 Page 2 of 5
TRAINING PROFILE
Training Objective
McWane has many long-time employees that will be retiring in the Company over the next few years. The remaining workforce must be trained and skilled sufficiently to assume leadership roles.
Training is summarized below. Additional details are provided in Attachment 1 - Group and Job Title Details of this Panel Proposal.
# Group Characteristics # of Trainees
Reimbursement Rate
Avg. Hours
Cost Per Trainee
Min – Max Hour
1 Retrainees 253 $18.00 39 $702.00 8 - 200
2 Veteran Retrainees 19 $22.00 40 $880.00 8 - 200
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PROPOSED TRAINING PROJECT DETAILS
Provided here are the details on the proposed Training Project.
1. Company Background
Founded in 1903, McWane is a family-operated company that manufactures pipes, valves, hydrants, fittings and plumbing products. Training will also be delivered to McWane’s subsidiary companies, AB&I, a division of McWane, Inc. (AB&I) and Anaco, a division of McWane, Inc.(Anaco) AB&I manufactures cast iron pipes and fittings at its Oakland facility, and ships products from its distribution center in the City of Industry. Anaco manufactures no-hub stainless steel couplings at its Corona facility. McWane products are used in a variety of infrastructure projects, including hotels, stadiums, hospitals, schools, and were even used at Alcatraz.
2. Current Training Project Details
Provided here are details on the purpose of the training, a summary of the marketing plan and support costs.
Purpose of Training
McWane has many long time employees retiring over the next few years. These employees have institutional knowledge and hold leadership positions. McWane is requesting ETP assistance to train the next generation of employees to assume leadership roles. In addition, Production Workers advancing to leadership positions must be trained in math, literacy, and computer training.
McWane will provide training on new manufacturing processes. Workers will receive training on a new Enterprise Resource Planning (ERP) system to better track customer requests and purchases, material orders and inventory. Training will include Six Sigma, Lean manufacturing and Quality Control tools.
McWane will also provide training on new technology. The Company developed a new coating system for its pipes which reduces odor and fume leakage. This coating is currently in the testing phase, and workers require training for production stage. McWane recently added the “no-bake” molding, which uses chemical resins to bind together the sand used in molding, allowing the Company to produce larger castings. Workers need training to properly use the advanced chemicals and produce the new and larger products.
McWane also utilizes a large manufacturing robot for grinding large pipes. Employees need training to properly program and operate it.
Training Infrastructure and Administrative Plan
Training will be provided by subject matter experts and training vendors. Classes will be conducted at the Company’s facilities in Corona, Oakland and City of Industry. Classes may be delivered as E-learning to allow training to be delivered to trainees at multiple facilities. This training will be delivered at the 1:20 trainer-to-trainee ratio.
Director of Business Operations will oversee all ETP training. This includes scheduling training at the Oakland facility, where the majority of the training will take place, and at the City of Industry facility, which consists of three people. She will coordinate training in Corona with the facility’s HR Manager. Training records will all be sent to the Company Representative at the Oakland facility, where they will be entered and stored.
McWane actively participates in Veteran outreach by participating in several Veteran
Training Proposal for McWane, Inc. 17-0661 Page 4 of 5
Job fairs on a yearly basis.
Substantial Contribution
N/A
3. Sample Curriculum
Provided below is a summary of the methods by which training will be delivered including a sample of the courses that will be offered.
Each of the Trainee groups will be able to take courses under the various delivery methods.
Delivery Method Classroom/Simulated Laboratory
Training Type/Level Sample Classes
Business Skills 1st Time Lead: Preparing for increased responsibilities, Leadership, Communications
Continuous Improvement Skills Six Sigma, Lean Manufacturing, Quality Control
Manufacturing Skills Production Machinery, Assembly Procedures
Enterprise Resource Planning System, Microsoft Office
Hazardous Materials Skills - (E-Learning/Computer Based Training)
Hazardous Waste Material Handling, Hazardous Chemical Cleaning/Handling, Hazardous Waste Cleaning
4. Additional Company or Training Project Details
4.1 Program Waivers
The next table lists the various waivers and supporting justifications for training that apply to this proposed Training Project.
Waivers/Justification Type Summary
None Identified
4.2 Subcontractor Summary
The applicant has retained the services of the following Subcontractor(s).
Subcontractor Type Subcontractor Name City Service Cost
Development None N/A N/A
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Administrative None N/A N/A
Training TBD TBD TBD
4.3 Previous ETP Project Summary
None
4.4 Supporting Panel Proposal Documentation
Provided in Attachments 1, 2 and 3 is additional application details on the intended training population, the detailed curriculum, and associated program characteristics that are related to this proposed Training Project.
Attachment 1 – Group and Job Title Details
Training Proposal for McWane, Inc. : 17-0661 Attachment 1: Page 1
The proposed Training Project includes training for the following Trainees, organized by training group.
Group #: 1 – Retrainee
County ETP Minimum Wage
Alameda County $17.63
Los Angeles County $16.96
Riverside County $16.16
Job Title Estimated Number of Trainees
Base Wage Range Health Benefits Applied
Post-Retention Wage
Alameda County
Electricians 6 $29.00 - $35.00 $0.00 $29.00
Leadmen 21 $22.45 - $30.00 $0.00 $22.45
Leadmen in Training 5 $20.50 - $27.00 $0.00 $20.50
Machine Operators 30 $22.00 - $26.00 $0.00 $22.00
Managers 7 $30.00 - $50.00 $0.00 $30.00
Mechanics 30 $27.00 - $32.00 $0.00 $27.00
Production Workers 30 $17.60 - $20.50 $0.03 $17.63
Sales (Inside and out) 13 $25.00 - $50.00 $0.00 $25.00
Supervisors 18 $24.00 - $30.00 $0.00 $24.00
Supervisors in Training 11 $20.50 - $25.00 $0.00 $20.50
Attachment 2 – Training Delivery and Curriculum Listing
Training Proposal for McWane, Inc.: 17-0661 Attachment 2: Page 1
Provided below are details on the types of training planned for this proposed Training Project.
Delivery Method Classroom/Simulated Laboratory
Training Type/Level Planned Course Offerings
Business Skills
Project Management
Inventory Control
Communications
Critical Thinking/Problem Solving
Negotiations Skills
Supervising People
Organizational Development
Team Problem Solving/Managing Conflict & People
Customer Relations
Team Building/Leadership
1st Time Lead: Preparing for increased Responsibilities
Business Math
Business Writing
Accounting
Computer Skills
Microsoft Office Suite (Advanced/Intermediate)
Enterprise Resource Planning System
Computer Skills – Advanced Ratio 1:10
Robotics
Continuous Improvement
5S
Problem Solving/Critical Thinking
Data Collection
7 Basic Tools of Quality
Six Sigma
Quality Control
Lean Manufacturing
Hazardous Materials
HAZMAT
HAZWOPER
OSHA 10/30
Literacy Skills
Mathematical Literacy
Business Literacy
Attachment 2 – Training Delivery and Curriculum Listing
Training Proposal for McWane, Inc.: 17-0661 Attachment 2: Page 2
Delivery Method Classroom/Simulated Laboratory
Training Type/Level Planned Course Offerings
Manufacturing Skills
Production Machinery
Assembly Procedures
Delivery Method E-Learning/ Instructor Led Distance Learning
Training Type/Level Planned Course Offerings
Business Skills
Project Management
Inventory Control
Communications
Critical Thinking/Problem Solving
Negotiations Skills
Supervising People
Organizational Development
Team Problem Solving/Managing Conflict & People
Customer Relations
Team Building/Leadership
1st Time Lead: Preparing for increased Responsibilities
Business Math
Business Writing
Accounting
Computer Skills
Microsoft Office Suite (Intermediate/Advanced)
Enterprise Resource Planning System
Continuous Improvement
5S
Problem Solving/Critical Thinking
Data Collection
7 Basic Tools of Quality
Six Sigma
Quality Control
Lean Manufacturing
Delivery Method E-Learning – CBT
Training Type/Level Planned Course Offerings
Hazardous Materials
Hazardous Waste Material Handling 1 hour
Hazardous Chemical Cleaning/Handling 1 hour
Attachment 2 – Training Delivery and Curriculum Listing
Training Proposal for McWane, Inc.: 17-0661 Attachment 2: Page 3
Delivery Method E-Learning – CBT
Training Type/Level Planned Course Offerings
Hazardous Waste Cleaning 1 hour
Delivery Method Productive Lab (PL)
Training Type/Level Planned Course Offerings
Computer Skills – Advanced Ratio 1:1
Robotics
Manufacturing Skills
Assembly Procedures
Production Machinery
PL Justification
Need for Productive Laboratory Training
The Company requests additional PL hours above the standard cap of 60 to 80 hours. Trainees will receive up to 80 hours of PL training at a 1:1 trainer-to-trainee ratio. McWane will train employees on recently added coating and molding processes and equipment, and how the robot can assist new processes. Employees must learn new techniques in a productive environment. Because the new molds and new chemical coatings are entirely new processes, trainees will require many hours of training to learn how the process changes for different size pipes. Additionally, since the new molds allow larger pipes to be produced, existing machinery and processes must be modified to accommodate the larger pipes. Production Workers and Mechanics will receive between 40 and 80 hours of training depending on their areas of expertise.
Equipment/Processes to be Used
Casting/molding, cupola training, coating, injection molding, press, tool-and-die, assembly procedures, robot programming/operation. This includes assembly procedures and non-robotic production machinery such as that used in creating the molds.
Trainer Qualifications Experienced Subject Matter Experts, Equipment Vendors, recipients of Train-the-Trainer training
Attachment 3 - Training Project Characteristics Details
Training Proposal for McWane, Inc.: 17-0661 Attachment 3: Page 1
Provided in the table are details on the training characteristics.
Characteristic Program Summary
Retrainee - Veterans To help provide veterans with necessary skills to enter the workforce and improve opportunities for advancement in high wage, secure jobs, the Panel incentivizes training for veterans. Training for veterans is reimbursed at a higher rate. Training hours may consist of up to 50% literacy or other basic skills training. Full-time employment is required for a minimum of 30 hours per week during 90-day retention period (or 500 hours within 272 days). The Retrainee Cap on hours (200) may be modified. Standard wage requirements apply.
