Title: Supplier Excellence Alliance (SEA) Process Owner Forum 2.1.1 Job Skills
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
- mikek_at_warmelin.com
2Warmelin 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.
Company Vision
- 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 ( _at_ Phase 3 )
3Warmelin Precision Products
- Total Manufacturing Area 25,000 SF
- In the process of adding an additional 10,000 SF
- Present Manufacturing Capabilities
- Precision Milling
- Precision Turning
- ID/OD Grinding
- Mechanical Assembly Clean Room
4Our Simple Philosophy
DELIVER QUALITY PRODUCTS ON TIME
PROVIDE VALUE FOR THE CUSTOMER
INFRASTRUCTURE CONTINUOUS
IMPROVEMENT CELLULAR MFG RELATIONSHIPS
INVEST IN THE FUTURE
APPLY SIMPLE MODELS TO COMPLEX SITUATIONS
5Our Commitment to Relationships
- Business of Developing and Fostering
Relationships - Customers
- Suppliers
- Employees
- PROMOTES MUTUAL SUCCESS
6Our Infrastructure
AGGRESSIVE TRAINING PROGRAMS
SEEK INVEST IN HIGHLY MOTIVATED PEOPLE
- PROMOTING
- COMMITMENT
- ACCOUNTABILITY
- QUALITY
PROCESS DRIVEN ORGANIZATION
UTILIZING CONTROL SYSTEMS
FOCUS ON GOALS RESULTS
7SEA Roadmap 2011
Certification Level Bronze OTD 90-94.9, PPM
lt15,000 Silver OTD 95-98.9, PPM lt10,000 Gold OTD
99-100, PPM lt2,500
82.1.1 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?
9WPP STRATEGIC PLAN FY2011
Vision Statement We will increase revenue 20 by
2012 using lean processes company wide to become
the preferred source for Complex machined parts
in the aerospace industry
STRATEGIC GOALS
- Eliminate Escapes
- Champion Mike Khavar
- Metrics Escapes, PPM
- Actions
- Establish Metric Definitions Methodology
- Analyze root cause and corrective actions for
each escapes
On Time Delivery Champion Dan Bohannon Metrics
Cust. OTD Chart Actions 1. Analyze 10 latest
each month using Root Cause Analysis, Trends,
Actions
- S.E.A Certification
- Champion Mike Khavar
- Metrics S.E.A Metrics
- Actions
- Establish Action Plans
- Employee Site Visits
- 3. Submit New Change to Management
Plan to S.E.A. For
Comment
Monthly Management Review on 2nd Tuesday of Each
Month Chair Doug Horton Ron Bohannon Attendee's
Mike Khavar, Dan Bohannon, Arturo Sanchez,
Sherri Henkel, Nelia Avelino, Rue Segovia Agenda
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.
102.1.1 Job Skills Cross-Training Certification
Process
Name of the Process Job Skills Cross-Training Certification Level of Maturity 3 Date Achieved 12/15/10
Process Champion Mike Khavar Mike Khavar Mike Khavar Mike Khavar Mike Khavar
Process Owner Mike Khavar Mike Khavar Mike Khavar Mike Khavar Mike Khavar
Purpose 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 criteria Train employees Certify employees Ensure cross-training Maintain training and certification Records Describe what the business demands of the process and what the customer(s) expect from the process and quality requirements Define certification criteria Train employees Certify employees Ensure cross-training Maintain training and certification Records Describe what the business demands of the process and what the customer(s) expect from the process and quality requirements Define certification criteria Train employees Certify employees Ensure cross-training Maintain training and certification Records Describe what the business demands of the process and what the customer(s) expect from the process and quality requirements Define certification criteria Train employees Certify employees Ensure cross-training Maintain training and certification Records Describe what the business demands of the process and what the customer(s) expect from the process and quality requirements Define certification criteria Train employees Certify employees Ensure cross-training Maintain training and certification Records
Start of the Process Identification of required job skills certification Identification of required job skills certification Identification of required job skills certification Identification of required job skills certification Identification of required job skills certification
End of the Process Employees certified in jobs skills Employees certified in jobs skills Employees certified in jobs skills Employees certified in jobs skills Employees certified in jobs skills
Performance Metric Number of training hours per month / total labor hours Number of certification issued per month Number of training hours per month / total labor hours Number of certification issued per month Number of training hours per month / total labor hours Number of certification issued per month Number of training hours per month / total labor hours Number of certification issued per month Number of training hours per month / total labor hours Number of certification issued per month
Supplier Name Specific Input Specific Input Specific Input Specific Input Specific Input
Master Trainer Create Training Curriculum Create Training Curriculum Create Training Curriculum Create Training Curriculum Create Training Curriculum
Certification Criteria Certification Criteria Certification Criteria Certification Criteria Certification Criteria
Training Schedule Training Schedule Training Schedule Training Schedule Training Schedule
Identification of Trainees (Cross-Training Matrix) Identification of Trainees (Cross-Training Matrix) Identification of Trainees (Cross-Training Matrix) Identification of Trainees (Cross-Training Matrix) Identification of Trainees (Cross-Training Matrix)
User Name Specific Responsibilities Specific Responsibilities Specific Responsibilities Specific Responsibilities Specific Responsibilities
Master Trainers Training and certification of team members Training and certification of team members Training and certification of team members Training and certification of team members Training and certification of team members
Customer Name Specific Output Specific Output Specific Output Specific Output Specific Output
Employees Job Skills certified Job Skills certified Job Skills certified Job Skills certified Job Skills certified
11SEA-LES PROCESSES SEA-LES PROCESSES SEA-LES PROCESSES SEA-LES PROCESSES
Track Champions Process Owners (may be the same person as the Champion) Owners
1. Leadership Culture Ron Bohannon 1.1.1 Strategic Planning Ron
1. Leadership Culture Ron Bohannon 1.1.2 Leadership Communication Ron
1. Leadership Culture Ron Bohannon 1.1.3 Organizational Performance Review Ron
1. Leadership Culture Ron Bohannon 1.1.4 Continuous Improvement Management (usually same as Operational Excellence Champion) Ron
1. Leadership Culture Ron Bohannon 1.1.5 Workforce Development Integration (usually same as Workforce Development Champion) Ron
1. Leadership Culture Ron Bohannon 1.2.1 Supply Chain Integration Process Ron
1. Leadership Culture Ron Bohannon 1.3.1 New Product Startup Process Ron
2. Workforce Development Mike Khavar 2.1.1 Job Skills Cross Training Certification Mike
2. Workforce Development Mike Khavar 2.2.1 Continuous Improvement Process Mike
3. Operational Excellence Mike Khavar 3.1.1 Kaizen Process Dan
3. Operational Excellence Mike Khavar 3.1.2 6S Visual Workplace Process Dan
3. Operational Excellence Mike Khavar 3.1.3 Quick changeover/SMED Process Dan
3. Operational Excellence Mike Khavar 3.2.1 Material Management Process Sherri
3. Operational Excellence Mike Khavar 3.2.2 Production Planning Process Dan
3. Operational Excellence Mike Khavar 3.2.3 Development Process Russ
122.1.1 Job Skills Cross - Training Certification
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
-
- 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
- Champions
- Process Owners
- Master Trainers
- Collect Data
- Compile data for review
- Training Objectives
- Process Analysis
- Process Owner feedback
-
- Feedback
- Collect Feedback.
- Improve Process.
Training Plans
Monthly All-Hands Employee Meetings to review
company performance, goal status, training
progress and obtain employee feedback.
Monthly Management Review Meetings of Goals,
Targets, Action Plans, Champion Reports and
training updates.
13All-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
14Short Long Term Goals
- Near-Term (12 mos.)
- Achieve 94 OTD for all value streams
- Reduce PPM on all value streams to lt 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 lt 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 lt 2000
- Continue lean implementation - achieve inventory
turns of 5.6 - Achieve a 20 growth
15WPP 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
16WPP 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/6Ss skills
- Certified Internal Auditor (CIA) skills
- Total Productive Maintenance (TPM) skills
- SMED/OEE skills
- GDT skills
- APQP/PCPX/PPAP skills
17WPP Employee Training menu curriculum
- BUSINESS SKILLS
- Project Management skills
- Business Performance Skills (Accounting,
Financial Controls, Inventory) - Material Management skills
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21Cross-Training Matrix
22Training Room
23M easure E verything T hat R esults Customer
Centric I n C ustomer S atisfaction
24 Thank You
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