PROPOSED TRAINING PROJECT DETAILS Training Proposal for C&D Zodiac: 17-0621 Page 1 of 7 TRAINING PROPOSAL FOR C&D Zodiac, Inc. 17-0621 Panel Meeting Date: 08/25/2017 Regional Office: San Diego Regional Office Analyst Name: Davey, Joe Type of Proposal: Single Employer Contract (SE) Funding Source: Out-of-State Competition FUNDING OVERVIEW Provided here is a summary of the funding for the proposed Training Project. TOTAL ETP FUNDING: $626,778 Program & Admin Cost Support Cost Substantial Contribution (50%/15%) Total In-Kind $739,350.00 N/A $112,572 $765,000.000 APPLICANT PROFILE Company Summary C&D ZODIAC, INC., (Zodiac), (http://www.zodiacaerospace.com) designs and manufactures aircraft interior components, such as overhead bins, cabinets, galleys, lighting, stairways and doors. Zodiac and its sister company, Driessen Aircraft Interior Systems, will participate in this project together. Both companies are owned by Zodiac Aerospace of France. Industry Sector(s) Manufacturing Priority Industry Yes No. of Employees (Applicant) State: 3,600 US: 5,700 World Wide: 32,388 Turnover Rate (Applicant) 5.00% Repeat Contractor Yes High Unemployment Area No Unions N/A
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PROPOSED TRAINING PROJECT DETAILS
Training Proposal for C&D Zodiac: 17-0621 Page 1 of 7
TRAINING PROPOSAL FOR
C&D Zodiac, Inc.
17-0621
Panel Meeting Date: 08/25/2017
Regional Office: San Diego Regional Office
Analyst Name: Davey, Joe
Type of Proposal: Single Employer Contract (SE)
Funding Source: Out-of-State Competition
FUNDING OVERVIEW
Provided here is a summary of the funding for the proposed Training Project.
TOTAL ETP FUNDING: $626,778
Program & Admin Cost Support Cost Substantial Contribution
(50%/15%) Total In-Kind
$739,350.00 N/A $112,572 $765,000.000
APPLICANT PROFILE
Company Summary
C&D ZODIAC, INC., (Zodiac), (http://www.zodiacaerospace.com) designs and manufactures aircraft interior components, such as overhead bins, cabinets, galleys, lighting, stairways and doors. Zodiac and its sister company, Driessen Aircraft Interior Systems, will participate in this project together. Both companies are owned by Zodiac Aerospace of France.
Industry Sector(s) Manufacturing
Priority Industry Yes
No. of Employees (Applicant) State: 3,600 US: 5,700 World Wide: 32,388
Turnover Rate (Applicant) 5.00%
Repeat Contractor Yes
High Unemployment Area No
Unions N/A
PROPOSED TRAINING PROJECT DETAILS
Training Proposal for C&D Zodiac: 17-0621 Page 2 of 7
TRAINING PROFILE
Training Objective
C&D Zodiac will provide training to its employees at nine California locations in necessary skills required to improve efficiency and productivity.
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 775 $18.00 53 $954.00 8-200
PROPOSED TRAINING PROJECT DETAILS
Training Proposal for C&D Zodiac: 17-0621 Page 3 of 7
Provided here are the details on the proposed Training Project.
1. Company Background
Founded in 1972 and headquartered in Huntington Beach, Zodiac designs and manufactures aircraft interior components, such as overhead bins, cabinets, galleys, lighting, stairways and doors. C&D Zodiac, Inc. and its sister company, Driessen Aircraft Interior Systems, will participate in this project together. Both companies are owned by Zodiac Aerospace of France. Training will be conducted at the following location(s): Cypress, Garden Grove, Huntington Beach, Ontario, Rancho Cucamonga.
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
This will be Zodiac’s fifth ETP Agreement, fourth in the last five years. The previous Agreements (ET13-0236 and ET11-0199) focused on new design and engineering processes that occurred in advance of production to improve overall efficiency; reduce cost; and retain product quality. In its most recent Agreement (ET15-0424), much of the training was focused on Manufacturing Skills for employees in composite plastic and injection-mold manufacturing techniques. This proposal will continue training from the previous Agreement, with a focus on production efficiency. Training will not be duplicated. Zodiac’s two largest customers are increasing the production rate of new narrow-body airplanes, from 42 to 57 planes per month. This requires Zodiac to also increase production. In addition, as Zodiac expands into other markets, employees will need to be trained in how to reconfigure seats, overhead bins, and other aircraft interior components. Reconfiguring will change production specifications for both engineers and production workers.
Training Infrastructure and Administrative Plan
Zodiac retained National Training Company, Inc. to assist with project administration. In addition, the Company has designated internal staff to schedule and oversee training as well as collect and submit training rosters.
Marketing Plan (MEC Only)
N/A
Support Cost Description (MEC Only)
N/A
Substantial Contribution Description
C&D ZODIAC, INC. is a repeat contractor with payment earned in excess of $250,000 for incumbent workers at the locations below within the past five years. In its most recent Agreement, (ET15-0424), Zodiac was assessed a 30% substantial contribution for past earnings in excess of $250k for incumbent workers, most of whom were located at the Huntington Beach facility. Under this proposal, the new ETMS cost structure allows for the identification and assessment of each facility by location. Therefore, facilities will be assessed the respective substantial contribution based on prior (and projected) earnings for incumbent workers. Accordingly, reimbursement for trainees at these locations will be reduced as shown in the table below to reflect the Company’s Substantial Contribution to the cost of training.
PROPOSED TRAINING PROJECT DETAILS
Training Proposal for C&D Zodiac: 17-0621 Page 4 of 7
Location Substantial Contribution
Level Of Reduction
C&D ZODIAC, INC. $95,400.00 50.00%
Garden Grove-Lincoln $5,724.00 15.00%
La Palma $11,448.00 15.00%
Ontario-Grove $0.00 0.00%
Ontario-Quaker Ridge $0.00 0.00%
Rancho Cucamonga $0.00 0.00%
Cypress $0.00 0.00%
Garden Grove-Industry $0.00 0.00%
Driessen Aircraft Interior Systems, Inc.
$0.00 0.00%
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.
Percentage of Curriculum that is Productive Lab: 5%
4. Additional Company or Training Project Details – Keep all subparagraphs
Provided here is additional information relative to the proposed Training Project.
4.1 Program Justifications
The next table lists the various waivers and supporting justifications for training that apply to this proposed Training Project.
Waivers/Justification Type Summary
Productive Laboratory Training Zodiac states that classroom instruction is an inadequate method of training on the Company’s proprietary thermo-forming and injection molding equipment. The most effective method of learning how to safely and efficiently operate these complex machines requires hands-on experience. Zodiac requests a maximum trainer-to-trainee ratio of 1:3. The company states that trainees work in small groups on the same product, and, to ensure consistent instruction, need to be trained together. Most of the PL training will be conducted 1:1, but in these infrequent cases, small group training is more effective and efficient. Trainees who are proficient on one type of equipment will be cross-trained on new equipment.
Type of Equipment Component Fabrication Equipment, Component Forming Equipment, Plastic Thermoforming Equipment, Plastic Injection Molding Equipment, Production Assembly and Repair Equipment
4.2 Subcontractor Summary
The applicant has retained the services of the following Subcontractor(s).
Subcontractor Type Subcontractor Name City Service Cost
Development National Training Company, Inc. Irvine $15,000
Administrative National Training Company, Inc. Irvine 13%
Training N/A $0.00
PROPOSED TRAINING PROJECT DETAILS
Training Proposal for C&D Zodiac: 17-0621 Page 6 of 7
4.3 Previous ETP Project Summary - In this section the tables can be deleted if not needed
The table below summarizes the active performance under the ETP contract.
Active Contract(s) Elements
Summary
Agreement Number ET15-0424
Purpose of Training Company employees learned new manufacturing techniques and ways to reduce costs, improve product quality and improve on-time delivery.
Location(s) C&D Zodiac’s facilities in Los Angeles County (La Palma), Orange County (Huntington Beach, Garden Grove, Cypress); and San Bernardino County (Ontario (two locations) and Rancho Cucamonga.
Term 4/27/15 – 4/26/17
Approved Amount $306,060
Projected Earnings $306,060 $275,879 (incumbent)
Performance Percentage 100%
Other Notes ETP’s online tracking system shows 22,539 eligible training hours which is sufficient to support $284,644 (93%) in eligible earnings. The final closeout invoice is currently being processed by ETP.
This table summarizes Contractor's performance under prior contract(s) completed within the last five years.
Past Contract Activity
Agreement Number
Location(s) Term Approved Amount
Project Earnings Performance %
ET13-0236
Huntington Beach, Cypress, La Palma, Garden Grove, Ontario, Rancho Cucamonga, Santa Maria, Carlsbad
1/1/13 – 12/31/14
$447,750 $447,750 ($411,750 incumbent)
100% (92% incumbent)
ET11-0199
Huntington Beach, Cypress, La Palma, Garden Grove, Ontario, Rancho Cucamonga, Santa Maria, Carlsbad
4/11/11 – 4/10/13
$255,150 $86,776 34% (100% incumbent)
Notes ET11-0199 – C&D Zodiac’s second ETP project was Job Creation training for newly hired retrainees. Zodiac hired and trained more than 400 new employees. Despite providing more than 15,000 hours of training, very few of these trainees received the minimum 24 hours for full reimbursement due to internal difficulties in scheduling and maintaining rosters.
PROPOSED TRAINING PROJECT DETAILS
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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 C&D Zodiac, Inc.: 17-0621 Attachment 1: Page 1 of 3
The proposed Training Project includes training for the following Trainees, organized by training group.
Explain the need for productive laboratory (PL) training.
Classroom instruction is not an adequate means of training delivery because trainees must learn to operate proprietary equipment that requires hands on experience. The equipment is too large to bring into a classroom. Trainees who are proficient on one type of equipment will be cross-trained on new equipment. New hires will be trained on this equipment.
Describe the equipment/processes to be used in delivering PL training:
Component Fabrication Equipment, Component Forming Equipment, Plastic Thermoforming Equipment, Plastic Injection Molding Equipment, Production Assembly and Repair Equipment
Describe Trainer Qualifications:
Trainers will have at least 2 year of experience operating equipment before training others.
Attachment 3 - Training Project Characteristics Details
Training Proposal for C&D Zodiac Inc:17-0621 Attachment 3: Page 1 of 1
Provided in the table are details on the training characteristics.
Characteristic Program Summary
None Standard retrainee program with no additional characteristics.