Committed to Value and Quality Warmelin Precision Products 1 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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Presented by: Mike Khavar Manager, Quality & Continuous Improvements
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]. - PowerPoint PPT Presentation
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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
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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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(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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WPP Employee Training menu curriculum
• 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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WPP Employee Training menu curriculum
• 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
Committed to Value and QualityWarmelin Precision Products