Need
Poor product quality and excessive rework and scrap were traced to unfocused, ad hoc operator training. Further, significant resources were wasted and knowledge lost because separate facilities competed against each other.
Actions
Worked with 9 separate facilities to gain consensus on top priorities and buy-in on the benefits of joint participation. Managed design, development and implementation of country-wide technical OJT program, with agreement from plant management on core components common to all plants, and local customization to be implemented on a plant-specific basis.
Results
- Secured over $500,000 of funding to address priority needs.
- Achieved average reduction in scrap and rework of 10% - 15%.
- Decreased by over 40% the time required to bring new operators to full proficiency.
- Built a customizable technical training platform as a template for future development efforts.
