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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 mikek@warmelin.com. - 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
August 1, 2011
Presented by: Mike Khavar
Manager, Quality & Continuous Improvements
Certified Lean Expert & Master Black Belt
mikek@warmelin.com
Committed to Value and QualityWarmelin Precision Products
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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:
Committed to Value and QualityWarmelin Precision Products
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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
Committed to Value and QualityWarmelin Precision Products
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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
Committed to Value and QualityWarmelin Precision Products
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Our Commitment to Relationships
Business of Developing and Fostering Relationships
" Customers
" Suppliers
" Employees
PROMOTES MUTUAL SUCCESS
Committed to Value and QualityWarmelin Precision Products
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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
Committed to Value and QualityWarmelin Precision Products
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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?
Committed to Value and QualityWarmelin Precision Products
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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
Committed to Value and QualityWarmelin Precision Products
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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
Committed to Value and QualityWarmelin Precision Products
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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
Committed to Value and QualityWarmelin Precision Products
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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
Committed to Value and QualityWarmelin Precision Products
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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
Committed to Value and QualityWarmelin Precision Products
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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
Committed to Value and QualityWarmelin Precision Products
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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
Committed to Value and QualityWarmelin Precision Products
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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
Committed to Value and QualityWarmelin Precision Products
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WPP Employee Training menu curriculum
• BUSINESS SKILLS
– Project Management skills
– Business Performance Skills (Accounting, Financial Controls, Inventory)
– Material Management skills
Committed to Value and QualityWarmelin Precision Products
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Committed to Value and QualityWarmelin Precision Products
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Committed to Value and QualityWarmelin Precision Products
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Committed to Value and QualityWarmelin Precision Products
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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
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THE END
Thank You
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