Machining Training Section 1 Plus

7/28/2019 Machining Training Section 1 Plus

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SECTION 1

Training Objectives

Company History

AMT TechniquesCell Safety

PPE

Job Description


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1. 500% Improvement in Quality

2. Promote Creative Thinking

3. Increase Employee Knowledge and Growth

4. Improve Operator Problem Solving Skills

5. Improve Departmental Training Programs

TRAINING OBJECTIVES

Reduce Inventory


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ENKEI AMERICA, INC

COMPANY NAME Enkei America, Inc.

ADDRESS 2900 West Inwoood Dr.

Columbus, In. 47201ESTABLISHED September 1985 (Production start April 1987)

CAPITAL INVESTMENT 21 Million US dollars

SHARE HOLDERS 60% Enkei Corporation

20% Mc

20% Mic

EMPLOYEES 630

LAND AREA 155,515 m2

FACTORY AREA 35,881 m2

CUSTOMERSHonda of America, Honda of Canada, Honda of Alabama, Honda Access of America General

Motors

Mitsubishi Motors Manufacturing of America

Cami Automotive

Subaru I suzu Automotive

Southeast Toyota Distributors, Inc.

Toyota Motor Corporation

Nissan Motors Corporation U.S.A.

Aftermarket

HISTORY

1985 Sept-Established Company

1987 Feb-Start Trials

March-GM QAV Approved

April-First shipment to GM (3,600 Pieces)

Oct-Capacity reaches 50,000 per month

Feb-Plant Two start construction

1989 Dec-Plant Two CompleteFebCapacity reaches 75,000 per month

Jun-Start supplying to Japanese Companies in US.

May-Capacity reaches 120,000 per month

1995 June-MAP Factory Finished Construction

April-Received QS 9000 Certification

Dec-Map capacity reaches 60,000 per month

Total Enkei America Capacity reaches 180,000

Nov-MAP Facility added in Jacksonville, Florida

2001 Aug-Received QS 14001 Certification


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The techniques used in the AMT ( Analytical Method ofTraining ) Program are

designed so that the progress of the trainee can be measured. We break the entire job into

several individual tasks. These tasks can then be taught in phases. You will learn more

about this in the next few pages. The entire job is referred to as Single Cycle. Our goal

is to teach you the proper pace, quality and methods so you can do your job with

understanding and confidence.

The first part of training is to teach you by telling you and having you follow along in a

manual. We will quiz you to make sure that you are getting the general idea. We dontstop there.

The next part is to show you. We will get the materials needed then have you watch and

listen to how it is done. Next, we help you learn how to do it by talking you through

doing it yourself.

After that, we coach you by allowing you to do the job on your own while we oversee

you. This is where the measuring of your ability comes in. These measurements are

taking so that we can all see your progress. This way we can be sure that you are able tokeep up with the majority of your job tasks.

Can a person run 200 wheels, with quality, per day after 2 weeks of training and doing

single-cycle? No. You need to have a chance to work up to this physically. You will

have a trainer on-the-job after our single-cycle training to help you build up to the

expected goals. This phase is referred to as Job Management. Getting your pace and

organization such that you can run the entire job by yourself with the quality that is

expected of and by our company.

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AMT Techniques


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FEATURES OF AMT

AMT..

Is Structured OJT

Makes Full use of Present Staff

Emphasizes Job Skills Training Including:Job Safety

Job Quality

Job Methods

Job Output

Is a Success-Oriented System

Rapidly Trains Employees in 1/3 the Time

Promotes Measurement and Feedback

Develops Consistency

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AMT Characteristics


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What is Training?TRAINING

I s theTransferof Ski l l F rom one

Person to Another

I s the Conversion of Knowledge into

Performance

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AMT Characteristics


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What is Skill?

SKILL

I s the Abil i ty to Perform a Complete

Job Cycle With the Safety, Pace and

Quali ty of an Experienced, Expert

Employee

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AMT Characteristics


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What is Performance?PERFORMANCE

I s The Achievement of Measurable

Results

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AMT Characteristics


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Step-by-Step Approach to

Learning a Job---The AMT System

Selection

Basic

Exercises

JobExercises

Parts of

Job

Complete

Job

ShortRuns

Longer

Runs

Full Day

Expected

Production Level

Usual

Method

Skill Development Stamina Development

The Ability to Complete One Wheel

in Target (Single Cycle) Time

The Ability to Produce at the

Expected Rate for a Full Day

Job Management

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AMT Characteristics


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A B DC E F G H I J K L2

A+B K+LI+JG+HC+D E+F

A-D E-H I-L

A-E H-L

SINGLE CYCLE

S.C.

Ability To Machine 1 Wheel

1 HOUR

4 HOUR

8 HOUR

SKILL BUILDING CYCLE

Basic

Exercises

Job

Parts

Job

Exercises

Skill

Exercises

Single

Cycle

Stamina

Build

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AMT Characteristics


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TYPICAL RESULTS

Of

INEFFECTIVE TRAINING

Extended Learning Times

I ncomplete Learning

Var iable Quali ty

Variable Methods

H igher Turnover

Higher Absenteeism

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AMT Characteristics


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Name Job

Date Day in Training

JOB PART EXERCISES

Job & Target Results Job & Target Results

Section 2 Page 27

Wheel Parts

Can Explain Common

Terms Associated With

Critical DesignElements of Wheels

1. _____2. _____3. _____

4. _____

5. _____

Section 3 Page 39

Machines

Can Explain Basic

Machine Terminology

1. _____2. _____3. _____4. _____5. _____

Section 2 Page 31

Casting Flash Removal

Able to Recognize

When it is Necessary to

Remove Flashing and

Also Demonstrate How

to Remove

1. _____2. _____3. _____4. _____5. _____

Section 3 Page 47

Stamper Set Up

The Trainer Will Explain and

Demonstrate how to Set-Up

the Stamper.

Trainee Will Demonstrate

How to Set-Up Stamper

1. _____2. _____3. _____4. _____5. _____

Section 3 Page 33Process

Can Explain Common

Process Terms

1. _____2. _____3. _____4. _____5. _____

Section 4 Page 58Wheel Handling

Can Explain Correct Wheel

Handling Procedures for

Different Elements of the job

1. _____2. _____3. _____4. _____5. _____

Section 3 Page 36

Cell Specific Safety

Can Explain Location of

Machine SafetyFeatures Including

Energy Isolation Points,

and Safety Interlocks.

Also can Explain

Personal Protective

EquipmentRequirements andEmergency Stop

Procedures

1. _____2. _____3. _____4. _____

5. _____

Section 4 Page 68

Deburr Bolt Hole Area

Can Deburr all Bolt Holes

Within Target Time and WithAcceptable Quality (No Burrs

on Bolt Holes)

Target ____________Sec.5 Bolt Holes

1. _____2. _____3. _____4. _____

5. _____

AMT Techniques

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JOB PART EXERCISES


Section 4 Page 68

Deburr Window Area

Can Deburr all Window Areas

Within Target Time and With

Acceptable Quality (No Burrs

on Windows)

Target ____________Sec.5 Windows

1

2

3

4

5

Section 5 Page 101

TaggingProcedures

The Trainer Will Explain andDemonstrate how to Fill-OutTags for Pallets, etc.

Trainee Will Fill Out PalletTags Correctly

1

2

3

4

5

Section 4 Page 68

Deburr Valve Hole Area

Can Deburr all Valve Holes

Within Target Time and With

Acceptable Quality (No Burrs

on Valve Holes)

Target ____________Sec.5 Valve Holes

1

2

3

4

5

Section 5 Page 107

Related Forms ( Paperwork )

Can Explain How to Fill Out

and Report on SPC Charts,

Discrepant Wheel Report,

Downtime, Dimensional Checks

(Lathes and MC)

1

2

3

4

5

Section 5 Page 73Wheel Defect Recognition

The Trainer Will Coach the Train

During Machining to Make SuTrainee Recognizes and Disposes

Defective Wheels Correctly

12

3

4

5

Section 5 Page 138Tagging (Disposition ofWheels )

Can Explain Proper Disposition

Good Wheels, Defective Wheels, Q

Holds

12

3

4

5

Section 5 Page 96

100% Inspections

The Trainer Will Explain andDemonstrate how to Make100% Inspections on theLine.Trainees Will Demonstrate howto Measure 100% Dimensions

Correctly

1

23

4

5

Section 6 Page 112Tools and Gages

Can Explain Name, Use

Dimensional Gages

1

23

4

5

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AMT Techniques


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JOB PART EXERCISESJob & Target Results Job & Target Results

Section 6 Page 114

Machining CenterDimensional Inspections

The Trainer Will Explain andDemonstrate how to MakeMachining Center DimensionalInspections. Trainees WillDemonstrate how to MeasureDimensions Correctly

12

3

4

5

Section 6 Pages 153

SPC X Bar Chart Calculations

Can Calculate the sum and

Average of 5 Measurements(Positive and/or Negative with

100% Accuracy

12

3

4

5

Section 6 Page 124 Dimensional

Inspections

Trainer Will Coach the Traineein the Proper Method, Timingand Accuracy of MakingDimensional Checks

Trainee Will Correct Dimensional

Inspections Techniques

1

23

4

5

Section 6 Page 153

SPC R Chart Calculation

Can Calculate the Range of 5Measurements, Positive and/or

Negative With 100% Accuracy

1

23

4

5

Section 6 Page 149

SPC

Trainer Will Coach the Trainee

While SPC Procedures areCompleted.

Trainee Will Demonstrate

Capability to Complete SPC Checksand Make any Off-Set Adjustments

Necessary

1

23

4

5

Section 6 Page 154

SPC Chart Plotting

Can Plot Points on SPC Chart

From Results of MeasuringCharacteristics

1

23

4

5

Section 6 Page 150

SPC Indicators ofOut-of-Control Wheels

Can Explain Trend, Run,

Control Line Limits

1

23

4

5

Section 6 Page 166

Pilot Hole Adjustment

Trainer Will Demonstrate and

Explain Procedure for Making

Pilot Hole Adjustment.

Trainee Will Demonstrate andExplain the Procedure Show Steps

Necessary to Make the Adjustment

1

23

4

5

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AMT Techniques


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JOB PART EXERCISES


Section 6 Page 166Cap Hole Adjustment

Trainer Will Demonstrate andExplain Procedure for Making Cap

Hole Adjustment.

Trainee Will Demonstrate andExplain the Procedure Show Steps

Necessary to Make the Adjustment

Section 7 Page 177Start-Up Procedures

Trainer Will Explain andDemonstrate Procedures ForStarting-Up Line AfterWeekend Shutdown.

Trainee Will Demonstrate andExplain the Procedure andWhy it is Necessary.

1

2

3

4

5

Section 7 Page 168

Rougher Change and Adjustment

The Trainer Will Demonstrate andExplain the Correct Procedure for

Changing and/or Adjusting aRougher.

Trainee Will Demonstrate the

Procedure With Trainer Guidance.

1

2

3

4

5

Section 7 Page 177

Beginning Shift Procedures

Trainer Will Demonstrate andExplain Start-up Procedures at the

Beginning of Each Shift.

Trainee Will Demonstrate andExplain the Procedure and Why it

is Necessary

1

2

3

4

5

Section 7 Page 174

Chip Clean Out


Demonstrate Correct Chip CleanOut Procedures

The Trainee Must Demonstrate

How to Correctly and Safely CleanOut Chips

1

2

3

4

5

Section 7 Page 182

End-of-Shift Procedures

Trainer Will Demonstrate and

Explain End-of-Shift Procedures toShut the Line Down.

Trainee Will Demonstrate and

Explain the Procedure and Why itis Necessary.

1

2

3

4

5

Section 7 Page 186Shut Down Procedures

Trainer Will Explain and

Demonstrate Procedures ForShutting Line Down at Last Shift

Before Weekend.

Trainee Will Demonstrate andExplain The Procedure and Why it

is Necessary.

1

2

3

4

5

Section 7 Page 190

Controls

Can Identify and Explain Function

of all Control Panels Robot, TeachPendant, Lathe, MC, Orientator,

Dip Tank, etc.

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AMT Techniques


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JOB PART EXERCISES

Job & TargetResults Job & Target

Results

Section 7 Page 190

Clearing Alarms


Demonstrate how to Clear Alarms

Associated With Open Doors.

Servos, Orientators, Robots, etc.

Trainee Will Explain and

Demonstrate the Procedure With the

Trainer.

1

2

3

4

5

Section 7 Page 194

Job Management-

Dimensional Checks

The Trainer Will Explain Howto Maximize Time When

Making Dimensional Checksand Team Work Aspects of

Shared Responsibilities.

1

2

3

4

5

Section 7 Page 194

Job Management- Loading

Stocking

The Trainer Will Demonstrate and

Explain How to Load/Stock theLine For Optimum Job Management

and Less Downtime

The Trainee Will Loa/Stock the

Line Accordingly

1

2

3

4

5

Section 7 Page 195

Job Management-Lunch and

Break Relief

Trainer Will Explain TeamWork Aspect of Lunch and

Break Relief And How to

Maximize Productivity

1

2

3

4

5

Section 7 Page 194

Job Management-Shift Routines

Trainer Will Explain Shift Routines

That Will Maximize Productivityand Allow the Trainee to be in

Control of the Line.

1

2

34

5

Section 7

Skill Cycle

Trainee Will Demonstrate How

to Complete One Wheel in

Target Time (Loading,Deburring, Inspecting, Cleaning,

Handling, Palletizing)

Target:__________Seconds

1

2

34

5

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AMT Techniques


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JOB PART EXERCISES

Job & Target Results

Section 7

STAMINA BUILDUP (On Line

and Shift)

Trainee Will Be Assigned a JobManagement/ Stamina Buildup

Trainer Who Will Guide the TraineeThrough the Steps Necessary to

Meet Departmental Shift GoalsBased on Cycle Times, Cell, and

Wheel Style.

1

2

3

4

5

Section 7.1 HOUR RUNS

Trainee Will Work Uninterrupted

For One Hour to See How Many

Wheels Can be Produced With

Good Quality.

1 Hour Run Target____________Wheels

1

2

3

4

5

Section 7.2 TWO HOUR RUNS

Trainee Will Work UninterruptedFor Two Hours to See How Many

Wheels Can be Produced With

Good Quality.

2 Hour Run Target____________Wheels

1

2

3

45

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AMT Techniques


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Aside From Normal Plant Safety Rules, There are a Number ofCELL SPECIFIC Safety Rules

to be Practiced by Machining Operators.

1. Make Sure Long Hair is not Hanging Loose Around Conveyors, etc. as it Might Become

Entangled in the Conveyor.

2. Do not Walk on Conveyors.

3. Do not use Broken Wood Dividers or Pallets

4. Watch for Coolant on Floor (Slip Hazard). Report Coolant Leaks to Your Supervisor.

5. Watch out for Fork Trucks When Walking in Aisles and at the end of Cells.

6. Watch for Hoses Around Cell Areas (Trip Hazard)

7. Look Out for Frayed Wiring on Fans, etc. Be Sure Fan Cords are Not Sitting in Water.

8. When Hand-Loading Lathes, Watch out for Clamps.

9. Wear Gloves When Handling Wheels and Deburring (Sharp Edges Can Cut).

10. Keep Your Work Area Clean and Free From Debris.

11. Know Where all Emergency Stops are Located and their Function.

12. Do not Wear Loose or Baggy Clothing Around Cell Areas.

13. Carefully Handle all Roughers and Sharp Machining Tools.

14. Stay Clear of OP1, OP2, and Machining Center Doors When it is Necessary to Enter

the Cell.

15. Do Not Attempt to Catch a Dropped Wheel (Cut and Strain Hazard).

16. When Loading Wheels, Make Sure Fingers are not Pinched Between Wheels.

17. Be Sure to Wear all Personal Protective Equipment On Shop Floor at All Times.

a. Slip Resistant Boots

b. Eye Protection

c. Gloves

d. Ear Plugs

18. When Entering Cell, be Sure to Remove Key (or Plug) to Disable Robot

19. If More Than One Key (or Plug) is Missing, DO NOT START MACHINE UNTIL AREA

IS CLEAR OF PERSONNEL.

20. NO CLOSED CONTAINERS ANYWHERE ON SHOP FLOOR.


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Personal Protective Equipment Requirements

for Each Employee:

1. Eye Protection (Safety Glasses)

2. Slip Protection (Slip Resistant Boots)

3. Ear Protection (Ear Plugs)

4. Hand Protection (Gloves)

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CELL SAFETY


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MACHINE OPERATOR EXPECTATIONS

SUMMARY

Handling wheels as they come from machining operations, de-burr, inspectaccording to audit requirements and stack on pallets.

ESSENTIAL DUTIES AND RESPONSIBILITIES Include the following ( other

duties may be assigned):

Keep the line running at all times

Handle wheels

100% visual inspection using inspection sheets

De-burr all sharp edges

Remove all chips from wheel

Check plate and pin according to line and wheel model

Check Cap and Pilot 100%

Complete all dimensional audits and SPC checks on and by required times

Make minor offsets to machines

Lift wheels to skids

Tag all skids correctly

SUPERVISORY RESPONSIBILITIES

None

QUALIFICATIONS

To perform this job successfully, an individual must be able to perform each

essential duty satisfactorily. The requirements listed below are representative

of the knowledge, skill, and/or ability required. Reasonable accommodations

may be made to enable individuals with disabilities to perform the essential

functions.

Trained to read basic process sheets and blueprints to determine machining to

be done

Trained to perform Statistical Process Control checks, tagging procedures, and

de-burringAble to operate all production equipment within the department

Able to complete all required documentation relating to quality and quantity of

work.

Able to clearly identify casting, machining, and paint defects.

EDUCATION and/or EXPERIENCE

High School Diploma or General Education Degree ( GED ); one to three months

related experience and training.

LANGUAGE SKILLSRead instruction sheets. Write numbers and instructions. Discuss production

related issues with others.

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Job Description


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MATHEMATICAL SKILLS

Ability to add, subtract, multiply, and divide into all units of measure, using whole

numbers, common fractions, and decimals. Ability to compute rate, ratio, and percent

and to draw and interpret graphs.

REASONING ABILITY

Ability to apply common sense understanding to carry out instructions furnished in

written, oral, or diagram form. Ability to deal with problems involving concrete

variables in standardized situations.

CERTIFICATES, LICENSES, REGISTRATIONS

None required.

PHYSICAL DEMANDS

The physical demands described here are representative of those that must be met by

an employee to successfully perform the essential functions of this job. Reasonable

accommodations may be made to enable individuals with disabilities to perform the

essential functions.

While performing the duties of this job, the employee is regularly required to stand.

The employee frequently is required to walk, use hands to finger, handle, or feel; andreach with hands and arms. The employee must frequently lift and/or move up to 50

pounds. Specific vision abilities required by this job include close vision, peripheral

vision, and depth perception.

WORK ENVIRONMENT

The work environment characteristics described here are representative of those an

employee encounters while performing the essential functions of this job.

Reasonable accommodations may be made to enable individuals with disabilities to

perform the essential functions.

While performing the duties of this job, the employee is regularly exposed to wet

and/or humid conditions and moving mechanical parts. The noise level in the work

environment is usually loud.

The above statement ref lects the general detai ls co nsidered necessary to descr ibe the

princ ipal function s of the job id entif ied and sh all not be constru ed as a detai led

descr ipt ion o f al l of the work requirements that may be inherent in the job.

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Job Description

Documents

Machining Training Section 1 Plus