Why training is so important in manufacturing

1
Why training is so importantin manufacturing

• Joe Aresco
• Dynamic Gunver Technologies LLC

2
Why training is so importantin manufacturing

• Three important principles in executing
• our business plan
• 1 ) Leadership set the
  standard
• 2 ) Empowerment of our
  people
• 3 ) Data based decisions

3
Why training is so importantin manufacturing
Leadership set the standard Strong technically,
but lacking in leadership skills

• Business performance accountability
• balanced scorecard
• Team building
• Problem solving techniques
• Delegation of authority
• Conflict resolution
• Discipline and reward

• Supervisor development training
• Bullet proof manager seminars
• Project management training
• Train the trainer

Increase skills leading to performance
excellence
4
Why training is so importantin manufacturing
Empowerment of the people Enthusiastic workforce,
but micro managed

• Blue print reading
• Statistical process control
• Welding
• Rivet training
• Safety
• 6 s
• QCPC
• TPM

• Mistake proofing
• One piece flow
• Set up reduction
• Process mapping
• F.M.E.A.
• Lean mfg.
• Visual inspection
• Cross training, skills matrix

Leading 500 employees in the same direction ,
our competitive edge
5
(No Transcript)
6
Why training is so importantin manufacturing

• Data based decisions
• Strong data base, but decisions made through
  instincts

• Voice of the process
• QCPC
• NMR
• Customer complaints

• Statistical process control
• Sigma green belt
• ASQ six sigma black belt
• New horizons training

Confidence that the right things are changed
7
Success Stories
Why training is so importantin manufacturing
8

• Reason for improvement
• 1 laser was suspect of using more Compressed
  Helium
• Measurement data collection
• This department used GAS USAGE LOG
• Results from measurements This laser used 3
  times as much Helium as the other lasers (1 tank
  per day)
• Improvements
• Maintenance found a leaking hose and gage
• Leaks were fixed usage now is 1 tank every 3 days
• ANNUAL SAVINGS 32,500.00

9

• Reason for improvement
• To increase throughput (this operation is the
  bottleneck)
• Measurement data collection
• Set-up and cycle time analysis
• Improvements
• Reduced the amount of tools used from 8 to 4
• Cycle time reduced from 13 minutes to 4 minutes
• Setup time reduced from 40 minutes to 20 minutes
• ANNUAL SAVINGS 72,900.00

10
Why training is so importantin manufacturing

• Level loaded sales
• From 40 to 70
• (Cash Flow)
• Scrap rate
• From 2 to 0.8 of Sales
• Machine failure rate
• From 2.2 failures every day
• to 1 failure every 2 days

• Injuries
• From 93 to 41 Injuries
  
• Customer complaints
• From 66 to 25 Escapes
• Schedule performance
• From 92 to 98 on Schedule

Training in action
11
Why training is so importantin manufacturing
Leadership Empowerment Data based
decisions Leading 500 employees toward the same
goal
Our competitive advantage