proposed training project details training proposal … zodiac proposal with attach.pdf · proposed...
TRANSCRIPT
PROPOSED TRAINING PROJECT DETAILS
Training Proposal for C&D Zodiac: 17-0621 Page 1 of 7
TRAINING PROPOSAL FOR
C&D Zodiac, Inc.
17-0621
Panel Meeting Date: 08/25/2017
Regional Office: San Diego Regional Office
Analyst Name: Davey, Joe
Type of Proposal: Single Employer Contract (SE)
Funding Source: Out-of-State Competition
FUNDING OVERVIEW
Provided here is a summary of the funding for the proposed Training Project.
TOTAL ETP FUNDING: $626,778
Program & Admin Cost Support Cost Substantial Contribution
(50%/15%) Total In-Kind
$739,350.00 N/A $112,572 $765,000.000
APPLICANT PROFILE
Company Summary
C&D ZODIAC, INC., (Zodiac), (http://www.zodiacaerospace.com) designs and manufactures aircraft interior components, such as overhead bins, cabinets, galleys, lighting, stairways and doors. Zodiac and its sister company, Driessen Aircraft Interior Systems, will participate in this project together. Both companies are owned by Zodiac Aerospace of France.
Industry Sector(s) Manufacturing
Priority Industry Yes
No. of Employees (Applicant) State: 3,600 US: 5,700 World Wide: 32,388
Turnover Rate (Applicant) 5.00%
Repeat Contractor Yes
High Unemployment Area No
Unions N/A
PROPOSED TRAINING PROJECT DETAILS
Training Proposal for C&D Zodiac: 17-0621 Page 2 of 7
TRAINING PROFILE
Training Objective
C&D Zodiac will provide training to its employees at nine California locations in necessary skills required to improve efficiency and productivity.
Training is summarized below. Additional details are provided in Attachment 1 - Group and Job Title Details of this Panel Proposal.
# Group Characteristics # of Trainees
Reimbursement Rate
Avg. Hours
Cost Per Trainee
Min – Max Hour
1 Retrainees 775 $18.00 53 $954.00 8-200
PROPOSED TRAINING PROJECT DETAILS
Training Proposal for C&D Zodiac: 17-0621 Page 3 of 7
Provided here are the details on the proposed Training Project.
1. Company Background
Founded in 1972 and headquartered in Huntington Beach, Zodiac designs and manufactures aircraft interior components, such as overhead bins, cabinets, galleys, lighting, stairways and doors. C&D Zodiac, Inc. and its sister company, Driessen Aircraft Interior Systems, will participate in this project together. Both companies are owned by Zodiac Aerospace of France. Training will be conducted at the following location(s): Cypress, Garden Grove, Huntington Beach, Ontario, Rancho Cucamonga.
2. Current Training Project Details
Provided here are details on the purpose of the training, a summary of the marketing plan and support costs.
Purpose of Training
This will be Zodiac’s fifth ETP Agreement, fourth in the last five years. The previous Agreements (ET13-0236 and ET11-0199) focused on new design and engineering processes that occurred in advance of production to improve overall efficiency; reduce cost; and retain product quality. In its most recent Agreement (ET15-0424), much of the training was focused on Manufacturing Skills for employees in composite plastic and injection-mold manufacturing techniques. This proposal will continue training from the previous Agreement, with a focus on production efficiency. Training will not be duplicated. Zodiac’s two largest customers are increasing the production rate of new narrow-body airplanes, from 42 to 57 planes per month. This requires Zodiac to also increase production. In addition, as Zodiac expands into other markets, employees will need to be trained in how to reconfigure seats, overhead bins, and other aircraft interior components. Reconfiguring will change production specifications for both engineers and production workers.
Training Infrastructure and Administrative Plan
Zodiac retained National Training Company, Inc. to assist with project administration. In addition, the Company has designated internal staff to schedule and oversee training as well as collect and submit training rosters.
Marketing Plan (MEC Only)
N/A
Support Cost Description (MEC Only)
N/A
Substantial Contribution Description
C&D ZODIAC, INC. is a repeat contractor with payment earned in excess of $250,000 for incumbent workers at the locations below within the past five years. In its most recent Agreement, (ET15-0424), Zodiac was assessed a 30% substantial contribution for past earnings in excess of $250k for incumbent workers, most of whom were located at the Huntington Beach facility. Under this proposal, the new ETMS cost structure allows for the identification and assessment of each facility by location. Therefore, facilities will be assessed the respective substantial contribution based on prior (and projected) earnings for incumbent workers. Accordingly, reimbursement for trainees at these locations will be reduced as shown in the table below to reflect the Company’s Substantial Contribution to the cost of training.
PROPOSED TRAINING PROJECT DETAILS
Training Proposal for C&D Zodiac: 17-0621 Page 4 of 7
Location Substantial Contribution
Level Of Reduction
C&D ZODIAC, INC. $95,400.00 50.00%
Garden Grove-Lincoln $5,724.00 15.00%
La Palma $11,448.00 15.00%
Ontario-Grove $0.00 0.00%
Ontario-Quaker Ridge $0.00 0.00%
Rancho Cucamonga $0.00 0.00%
Cypress $0.00 0.00%
Garden Grove-Industry $0.00 0.00%
Driessen Aircraft Interior Systems, Inc.
$0.00 0.00%
3. Sample Curriculum
Provided below is a summary of the methods by which training will be delivered including a sample of the courses that will be offered.
Each of the Trainee groups will be able to take courses under the various delivery methods.
Delivery Method/Level Classroom/Simulated Laboratory
Training Type/Level Sample Classes
Business Skills Business Processes & Performance
Effective Communication Skills
Project Management
Computer Skills Advanced Computer-Aided Design
Engineering Applications
Manufacturing Resource Planning software
Continuous Improvement C&D Quality Systems
Root Cause Analysis
Operating Procedures
Manufacturing Skills Component Fabrication
Design Standards & Processes
Tools & Processes
Hazardous Materials Hazardous Material Handling (non-certified)
Material Safety Data Sheets (MSDS) Procedures
HAZMAT
PROPOSED TRAINING PROJECT DETAILS
Training Proposal for C&D Zodiac: 17-0621 Page 5 of 7
Delivery Method/Level Productive Laboratory (PL)
Training Type/Level Sample Classes Standard Hours
Productive Lab Component Fabrication Equipment 8-30
Component Forming Equipment 8-30
Plastic Injection Molding Equipment 8-30
Plastic Thermoforming Equipment 8-30
PL Details
Percentage of Curriculum that is Productive Lab: 5%
4. Additional Company or Training Project Details – Keep all subparagraphs
Provided here is additional information relative to the proposed Training Project.
4.1 Program Justifications
The next table lists the various waivers and supporting justifications for training that apply to this proposed Training Project.
Waivers/Justification Type Summary
Productive Laboratory Training Zodiac states that classroom instruction is an inadequate method of training on the Company’s proprietary thermo-forming and injection molding equipment. The most effective method of learning how to safely and efficiently operate these complex machines requires hands-on experience. Zodiac requests a maximum trainer-to-trainee ratio of 1:3. The company states that trainees work in small groups on the same product, and, to ensure consistent instruction, need to be trained together. Most of the PL training will be conducted 1:1, but in these infrequent cases, small group training is more effective and efficient. Trainees who are proficient on one type of equipment will be cross-trained on new equipment.
Type of Equipment Component Fabrication Equipment, Component Forming Equipment, Plastic Thermoforming Equipment, Plastic Injection Molding Equipment, Production Assembly and Repair Equipment
4.2 Subcontractor Summary
The applicant has retained the services of the following Subcontractor(s).
Subcontractor Type Subcontractor Name City Service Cost
Development National Training Company, Inc. Irvine $15,000
Administrative National Training Company, Inc. Irvine 13%
Training N/A $0.00
PROPOSED TRAINING PROJECT DETAILS
Training Proposal for C&D Zodiac: 17-0621 Page 6 of 7
4.3 Previous ETP Project Summary - In this section the tables can be deleted if not needed
The table below summarizes the active performance under the ETP contract.
Active Contract(s) Elements
Summary
Agreement Number ET15-0424
Purpose of Training Company employees learned new manufacturing techniques and ways to reduce costs, improve product quality and improve on-time delivery.
Location(s) C&D Zodiac’s facilities in Los Angeles County (La Palma), Orange County (Huntington Beach, Garden Grove, Cypress); and San Bernardino County (Ontario (two locations) and Rancho Cucamonga.
Term 4/27/15 – 4/26/17
Approved Amount $306,060
Projected Earnings $306,060 $275,879 (incumbent)
Performance Percentage 100%
Other Notes ETP’s online tracking system shows 22,539 eligible training hours which is sufficient to support $284,644 (93%) in eligible earnings. The final closeout invoice is currently being processed by ETP.
This table summarizes Contractor's performance under prior contract(s) completed within the last five years.
Past Contract Activity
Agreement Number
Location(s) Term Approved Amount
Project Earnings Performance %
ET13-0236
Huntington Beach, Cypress, La Palma, Garden Grove, Ontario, Rancho Cucamonga, Santa Maria, Carlsbad
1/1/13 – 12/31/14
$447,750 $447,750 ($411,750 incumbent)
100% (92% incumbent)
ET11-0199
Huntington Beach, Cypress, La Palma, Garden Grove, Ontario, Rancho Cucamonga, Santa Maria, Carlsbad
4/11/11 – 4/10/13
$255,150 $86,776 34% (100% incumbent)
Notes ET11-0199 – C&D Zodiac’s second ETP project was Job Creation training for newly hired retrainees. Zodiac hired and trained more than 400 new employees. Despite providing more than 15,000 hours of training, very few of these trainees received the minimum 24 hours for full reimbursement due to internal difficulties in scheduling and maintaining rosters.
PROPOSED TRAINING PROJECT DETAILS
Training Proposal for C&D Zodiac: 17-0621 Page 7 of 7
4.4 Supporting Panel Proposal Documentation
Provided in Attachments 1, 2 and 3 is additional application details on the intended training population, the detailed curriculum, and associated program characteristics that are related to this proposed Training Project.
Attachment 1 – Group and Job Title Details
Training Proposal for C&D Zodiac, Inc.: 17-0621 Attachment 1: Page 1 of 3
The proposed Training Project includes training for the following Trainees, organized by training group.
Group #: 1 – Retrainees
County ETP Minimum Wage
Los Angeles County $16.96
Orange County $17.22
San Bernardino County $16.16
Job Title Estimated Number of Trainees
Base Wage Range Health Benefits Applied
Post-Retention Wage
Los Angeles County
Administrative Staff 12 $12.86 - $21.17 $4.10 $16.96
Engineer 14 $23.64 - $35.66 $0.00 $23.64
Lead 10 $12.86 - $19.65 $4.10 $16.96
Managers/Supervisors 10 $20.27 - $43.35 $0.00 $20.27
Production Worker 20 $12.86 - $21.31 $4.10 $16.96
Technical Staff 14 $12.86 - $24.34 $4.10 $16.96
Orange County – 5701 Bolsa Ave, Huntington Beach
Administrative Staff 30 $13.12 - $21.17 $4.10 $17.22
Engineer 35 $23.64 - $35.66 $0.00 $23.64
Lead 20 $13.12 - $19.65 $4.10 $17.22
Managers/Supervisors 25 $20.27 - $43.35 $0.00 $20.27
Production Worker 60 $13.12 - $21.31 $4.10 $17.22
Technical Staff 30 $13.12 - $24.34 $4.10 $17.22
Orange County – 11240 Warland Drive, Cypress
Administrative Staff 15 $13.12 - $21.17 $4.10 $17.22
Engineer 15 $23.64 - $35.66 $0.00 $23.64
Lead 10 $13.12 - $19.65 $4.10 $17.22
Attachment 1 – Group and Job Title Details
Training Proposal for C&D Zodiac, Inc.: 17-0621 Attachment 1: Page 2 of 3
Job Title Estimated Number of Trainees
Base Wage Range Health Benefits Applied
Post-Retention Wage
Managers/Supervisors 10 $20.27 - $43.35 $0.00 $20.27
Production Worker 35 $13.12 - $21.31 $4.10 $17.22
Technical Staff 15 $13.12 - $24.34 $4.10 $17.22
Orange County – 12472 Industry Street, Garden Grove
Administrative Staff 6 $13.12 - $21.17 $4.10 $17.22
Engineer 7 $23.64 - $35.66 $0.00 $23.64
Lead 5 $13.12 - $19.65 $4.10 $17.22
Managers/Supervisors 5 $20.27 - $43.35 $0.00 $20.27
Production Worker 10 $13.12 - $21.31 $4.10 $17.22
Technical Staff 7 $13.12 - $24.34 $4.10 $17.22
Orange County – 7330 Lincoln Way, Garden Grove
Administrative Staff 6 $13.12 - $21.17 $4.10 $17.22
Engineer 7 $23.64 - $35.66 $0.00 $23.64
Lead 5 $13.12 - $19.65 $4.10 $17.22
Managers/Supervisors 5 $20.27 - $43.35 $0.00 $20.27
Production Worker 10 $13.12 - $21.31 $4.10 $17.22
Technical Staff 7 $13.12 - $24.34 $4.10 $17.22
Orange County – 17311 Nichols Lane, Huntington Beach
Administrative Staff 12 $13.12 - $21.17 $4.10 $17.22
Engineer 14 $23.64 - $35.66 $0.00 $23.64
Lead 40 $13.12 - $19.65 $4.10 $17.22
Managers/Supervisors 15 $20.27 - $43.35 $0.00 $20.27
Production Worker 39 $13.12 - $21.31 $4.10 $17.22
Production Worker 125 $13.12 - $24.34 $4.10 $17.22
Attachment 1 – Group and Job Title Details
Training Proposal for C&D Zodiac, Inc.: 17-0621 Attachment 1: Page 3 of 3
Job Title Estimated Number of Trainees
Base Wage Range Health Benefits Applied
Post-Retention Wage
San Bernardino County – 1945 S Grove Ave, Ontario
Administrative Staff 3 $12.06 - $21.17 $4.10 $16.16
Engineer 4 $23.64 - $35.66 $0.00 $23.64
Lead 3 $12.06 - $19.65 $4.10 $16.16
Managers/Supervisors 2 $20.27 - $43.35 $0.00 $20.27
Production Worker 10 $12.06 - $21.31 $4.10 $16.16
Technical Staff 3 $12.06 - $24.34 $4.10 $16.16
San Bernardino – 1940 Quaker Ridge Place, Ontario
Administrative Staff 3 $12.06 - $21.17 $4.10 $16.16
Engineer 4 $23.64 - $35.66 $0.00 $23.64
Lead 3 $12.06 - $19.65 $4.10 $16.16
Managers/Supervisors 2 $20.27 - $43.35 $0.00 $20.27
Production Worker 10 $12.06 - $21.31 $4.10 $16.16
Technical Staff 3 $12.06 - $24.34 $4.10 $16.16
San Bernardino - 11340 Jersey Blvd, Rancho Cucamonga
Administrative Staff 1 $12.06 - $21.17 $4.10 $16.16
Engineer 2 $23.64 - $35.66 $0.00 $23.64
Lead 1 $12.06 - $19.65 $4.10 $16.16
Managers/Supervisors 1 $20.27 - $43.35 $0.00 $20.27
Production Worker 10 $12.06 - $21.31 $4.10 $16.16
Technical Staff 5 $12.06 - $24.34 $4.10 $16.16
Attachment 2 – Training Delivery and Curriculum Listing
Training Proposal for C&D Zodiac Inc:17-0621 Attachment 2: Page 1 of 2
Provided below are details on the types of training planned for this proposed Training Project.
Delivery Method/Level Classroom/Simulated Laboratory
Training Type/Level Planned Course Offerings
Business Skills Business Processes & Performance
Customer Service and Sales Skills
Effective Communication Skills
Project Management
Computer Skills
\ Advanced Computer-Aided Design
Compliance Training
Computerized Reports
Engineering Applications
Hardware and Software Systems Tools
Manufacturing Resource Planning Software
MS Office (Advanced)
MS Office (Intermediate)
Web-Based Computer Applications
Continuous Improvement
Best Manufacturing Practices
Boeing and Airbus Inspection Procedures
C&D Quality Systems
Increase Productivity
Operating Procedures
Root Cause Analysis
Standard Work Instructions
Team Building
Team Problem Solving
Waste Identification
Manufacturing Skills (Hazardous Materials)
Emergency Response Team Training
Hazardous Materials Handling (non-certified)
Hazardous Waste
HAZMAT Training
Material Safety Data Sheets (MSDS) Procedures
Manufacturing Skills
Component Fabrication
Critical Design Review
Attachment 2 – Training Delivery and Curriculum Listing
Training Proposal for C&D Zodiac Inc:17-0621 Attachment 2: Page 2 of 2
Delivery Method/Level Classroom/Simulated Laboratory
Training Type/Level Planned Course Offerings
Cross-Functional Production Equipment Training
Design Standards and Processes
Engineering & Design Procedures
Forklift Procedures
Lean Manufacturing
Manufacturing Technologies
Overhead Bins
Plastic Injection Molding
Plastic Thermoforming
Practices & Procedures
Product Design & Development
Quality Control
Reading Technical Specifications
Standard Operating Procedures
Tools & Processes
Delivery Method/Level Productive Lab (PL)
Training Type/Level Planned Course Offerings
Manufacturing Skills
Component Fabrication Equipment
Component Forming Equipment
Plastic Injection Molding Equipment
Plastic Thermoforming Equipment
Production Assembly and Repair Equipment
PL Justification and Details
Explain the need for productive laboratory (PL) training.
Classroom instruction is not an adequate means of training delivery because trainees must learn to operate proprietary equipment that requires hands on experience. The equipment is too large to bring into a classroom. Trainees who are proficient on one type of equipment will be cross-trained on new equipment. New hires will be trained on this equipment.
Describe the equipment/processes to be used in delivering PL training:
Component Fabrication Equipment, Component Forming Equipment, Plastic Thermoforming Equipment, Plastic Injection Molding Equipment, Production Assembly and Repair Equipment
Describe Trainer Qualifications:
Trainers will have at least 2 year of experience operating equipment before training others.
Attachment 3 - Training Project Characteristics Details
Training Proposal for C&D Zodiac Inc:17-0621 Attachment 3: Page 1 of 1
Provided in the table are details on the training characteristics.
Characteristic Program Summary
None Standard retrainee program with no additional characteristics.