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Henry NortonTraining / Lean Manager
Graphic Plc
Training for Success
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Where PEOPLEmake the difference
Training for SuccessWEAF Innovation Showcase
Henry Norton
Graphic PLC
26th June 2013
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Business Overview
• Graphic is a specialist manufacturer of high reliability and performance critical printed circuit boards (PCB).
• In operation for 45 years (established in 1968)
• Facilities in UK, China, US and Denmark
• Key Markets: Defence, Aerospace, Security, Medical, Industrial and Broadcasting areas.
• Graphic Group currently employs 700 people across its four facilities
Rigid Flexible Flexi‐Rigid
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Business Challenges & Need for Innovation
Key Challenges for our Business• Reduced availability of PCB industry skills in UK and Europe
• Sustainability of internal skills
• Increasing product complexity
• Protecting our intellectual assets & technical capability
• Maintaining our strong competitive position
• Need for self‐sufficient and self reliant skills development
“Since people make things, work must begin with developing people”‐ Eiji Toyoda
Former Chairman of Toyota Motor Company
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Our Training & Development Mission
Project Aims• Develop a lean approach to training and development across the business
• Create an efficient and effective workforce to meet the business challenges
• Apply best training practices to enable and achieve standardised work
• Capture, store & disseminate the wealth of knowledge within our business
• Develop flexible multi skilled employees throughout Graphic
Programme Implementation
DESIGNTraining System
CREATETraining Resources
DELIVERTraining to employees
VERIFY& Continuous
Learning
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Origins of Job Instruction (JI) Method
Job Instruction is by no means a new idea…
• Born out of the Training Within Industry (TWI) program in the USA in WW2.
• Increase in conscription led to a reduced manufacturing workforce
• It was essential to implement a program that could train non skilled workers to a competent level in a short period of time
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Building the B17 at Boeing
In 1940 Boeing were faced with building the new B17 in a rush with an unskilled workforce.
They introduced a JI based training program that concentrated on:
• Keeping tools and materials in workers hands
• Keeping processes simple
• Training supervisors how to breakdown jobs
What did they see?
• 60% reduction in man hours per plane
• Fly a ways went from initial quote of 75 per month in 1941 to a peak of 364 per month in 1944
• Costs went from $242,000 in 1941 to $139,254 in 1944 a 34% reduction
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Innovative Approach to Training
New Training Approach• New training programme based upon TWI Job Instruction (JI) Model
• Experience and knowledge of skilled operators captured as best practice for each task as a JI lesson plan
• ‘Best practice’ delivered to employee using method that caters for people’s differences in learning styles
Core Elements• Creation of JI Training Resources (‘lesson plans’)
• Training Delivery
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Job Instruction Method – Key Elements
JI Training Resources• Engage & empower staff to create
lesson plans & learning content
• Determine current best practice
• Job Instruction for each part of the process broken into manageable chunks
• Emphasis on quality, attention to detail and understanding
• Capture knowledge consistently
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Anatomy of JI Work Breakdown Sheet
HOWQuality, productivity, EH&S aspects
WHYUnderstanding & reasoning behind key points
KEY POINTS REASONS
Basic Job Instruction (JI)* Format
*JI – Structure lesson plan for instructors
WHATMain actions undertaken during job
MAJOR STEPS
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Anatomy of JI Work Breakdown Sheet (2)
WHAT is done HOW it’s done WHY it’s done
Critical tasks!
Job description
Tool, Equip. & EH&S points
Learning links
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Job Instruction Method – Key Elements
Training Delivery• Trained instructors for each area
• Foundations of Training Delivery
• Combined approach to teaching
– Telling
– Showing
– Illustrating
– Questioning
• Address learning styles
– Visual, Aural, Kinaesthetic
• Verification, coaching & support
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How to Instruct (The 4‐Step Approach)
• Allows trainee to repeat the task on their own, explaining their actions as they do them.
• Leave trainee to perform the task with supervision
• Follow up by providing feedback and further coaching
• Verify trainee understanding
• Demonstrate the task to the trainee explaining what actions is performing and why
• Stress each Major Step, Key Point & Reason
• Prepare the trainee with an overview of the job, its purpose and the results desired
• Determine what they know already
Step 1: Prepare the Learner
Step 2: Present the Operation
Step 3: Try Out
Performance
Step 4: Follow Up
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1. Initial JI Training& Verification*
TRAINED
2. Operator GradeVerification*
ABILITY
3. Skilled Operator Grade Verification*
SKILLS
4. Expert Grade
KNOWLEDGE
Start 3 Months 6 Months 9 Months 12 Months
Training Schedule Milestones
*Verification – key component of successful training
• TASK (Trained / Ability / Skills / Knowledge) training levels
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Impacts & Benefits
• Training Time Reduction– 62% reduction in time needed to train new employees
• Productivity Improvement– 38% increase in productivity over previous training method
– £52,000 productivity increase per trainee with new JI method
• Waste Reduction– £21,900 saving from reductions in operator defects in Pilot area alone
• Increased Skill Level– 25% increase in departmental skill levels
• Developing & Empowering People– Teams helping to make incremental improvements
– Challenged and owning their own skill development
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Training for the Future
• Extend to other business functions
– Service & Admin departments, CAM / Front End, Sales, Purchasing, Accounts, …
• Accessible anywhere within the Business
– Electronic skills records & training matrix, training resources on internal WIKI, access via tablets
• Create Learning Organisation
– Aim for all skilled operators to receive training and coaching on how to train others
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Summary
• Our training innovation has allowed us to establish an in‐house training capability, creating learning resources to support ongoing training and delivering results
• Strengthening our business for the future by ensuring the integrity of our knowledge and the skills and expertise of our teams
• Involving and engaging everyone to help develop our skills collectively, building a culture for learning and improvement
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Performance in a Global Market Worldwww.graphic.plc.uk
Thank You