Chapter No.

E&T

EDUCATION
AND
TRAINING
PILLAR ACTIVITY
Presented By –

S.S.Bakshi

E & T Pillar Chairman

11.01.2012
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 Chapter No. 9
BACKGROUND E&T

No infrastructure
For skill
training

No systematic Accidents due

Approach to skill to
development Poor skill
Why Education
&
Training?

Majority workmen Defect

Without technical Due to
qualification Poor skill

Break down
Due to
Poor skill

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 Chapter No. 9

PILLAR STRUCTURE E&T

S. S. Bakshi
Pillar Chairman

Machine Shop Paint Shop LPDC Maintenance Purchase/Stores HR & Admin Quality

Akash Patil P.P. Y. C. Pimple K.O.Zanwar S.L.Kadu S.K.Zalte S. S. Kotgire

Deshmukh

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 Chapter No. 9

KMI / KPI / KAI E&T

PRE ASSESSMENT AUDIT HOME WORK
To review and revise KMI – KPI and KAI

Relationship between
Key Performance Index
and
Key Activity Index

Very Good Relation Good Relation

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 Chapter No. 9

OBJECTIVES AND TARGETS E&T

OBJECTIVES
1. To develop special skill through an active programme by giving
Knowledge, Skill Training & On the Job Training along with self
development.
2. New person can do the work in minimum possible time.
TARGETS
MACHINE SHOP PAINT SHOP LPDC SHOP

BM BM BM
Parameters UOM Target Target Target
06-07 06-07 09-10

Breakdowns due to
P poor skill & 11 0 2 0 6 0
knowledge

Defects due to poor

Q skill & knowledge Nos. 9 0 1 0 4 0

Accidents due to poor

S skill & knowledge
4 0 0 0 1 0

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 Chapter No. 9

MASTER PLAN E&T

Sr. 2006 - 07 2007 - 08 2008 - 09 2009 - 10 2010 - 11 2011 - 12

Activity
No
Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4

Collection of data for analysis & identify

1 the phenomenon which have occurred
due to poor skill & knowledge.

JIPM TPM award (category A) Final audit

CII health checkup audit on 06 Jan 2011
2 Identify existing knowledge and skill.
Analyze the skill gap and identify the

TPM kick off done in march 2007

3

Pillar Chairman Training at CII

training needs.
Preparation of training calendar as per

CII Pre assessment audit

4
training needs.
Conduct training program as per
5
training calendar.
Conduct the tests and Evaluate the
6
participants.
7 Evaluate the results of trainings.

8 Re Training if required.

9 Re – Evaluation.

10 Training for Skill Enhancement.

Activity Planed Activity In progress Activity Completed

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 Chapter No. 9
PRE ASSESSMENT AUDIT HOMEWORK POINTS E&T

Activity Planed Activity In progress Activity Completed

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 Chapter No. 9

STEPS FOR E&T PROGRESS E&T

HOMEWORK POINT BY JIPM AUDITORS

Develop Own Steps for implementation of “Education & Training” activities

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 Chapter No. 9

STEP 1 - APPROACH E&T

Skill Job
available requirement
Matching
Yes Assign job Found fit,
No
responsibility encourage for
Identify group or higher
individual training responsibility
needs

OFF THE JOB TRAINING Designing training ON THE JOB TRAINING

curriculum & training
calendar On the job training
Class room training
(shop floor)
Conduct training
based on skill
Visit effectively practicing Scale models preparations
requirement
TPM Companies & explain to others

Through Kaizens &

Attending seminars
One Point lesson

Evaluation of Training

Assign job
Retraining No Yes responsibility

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 Chapter No. 9
STEP 2 - EDUCATION AND TRAINING SYSTEM E&T
After introduction of TPM, an integrated Education and Training System was made along with our existing
system (Example as under) :

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 Chapter No. 9

STEP 3 - TRAINING FACILITIES E&T

Example of teaching material Training Material

Pillar wise Kaizen Displays One Point Lesson

Display of defects
Kaizens Implemented

Know Why Manual

Training Material
Modules for JH step 4

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 Chapter No. 9

STEP 4 – TRAINING RECORDS E&T

Attendance Sheet Training Feedback Form Feedback Analysis

Topic of Training : 7QC Tools Duration of training : 4 hours
Date : 31.08.2009 Total participates were to attend : 35
Trainer : Ms. Adlien Washington Actual attendance : 35

Relevance of training with Content of training Duration of the training program

your function

2 3 1 2
8 Below 8 Below Below
Average Average Average
12
Average Average Average
11
Good Good Good
13
Very Good Very Good Very Good
16

Excellent Excellent Excellent

14 15

Knowledge of the trainer Way of Presentation How do you rate your Knowledge on
the subject prior to this training
program?
Below 4 Below 2
1 Average Average 6 Below
Average 11 Average
Average
9 Average
11
Good Good 5 Good

Very Good Very Good Very Good

23
Excellent Excellent Excellent
20 13

Employees’ History Card Training Evaluation Form

HR/XX/FM-24
CODE NAME OF
DEPARTMENT TRAINING AREAS/ TOPIC TRAINING PERIOD SOURCE
NO. EMPLOYEE
00904 MR. PURAN SONI MAINTENANCE PMAC 24/03 TO 25/03/06 INTELTEK, PUNE

S-5 PLC PROGRAMING OCT'06 SIEMENS, PUNE

TRAINING ON PDCA APPROACH 22.09.07 INTERNAL

BBS ( BEHAVIOUR BASED SAFETY) 10.10.07 INTERNAL (Mr. NISHIYAMA )

20, 27/12/07 & 03, 19, 24,
EYP (ENHANCE YOUR POTENTIAL) EXTERNAL (Mr. ASHOK THUSSU)
30/01/2008
MESSUNG SYSTEMS PVT. LTD.,
SERVO SYSTEMS 24 ~ 26.12.07
PUNE
TQM 18/07/08 PROF. Y. TUSDA

MPS 2/8/2008 MACE, GURGAON

TPM 14-15/04/08 MR. K. MIZOTA

COMPETANCY MAPPING 12/8/2008 MS. IBHA LAL

ENERGY MANAGEMENT 23.06.2009 MACE, GURGAON

TPM 04.08.2009 MR. K. MIZOTA

ISO 14001 & EMS AWARENESS 09.09.2009 MR. SANJAY SHARMA

PMAC 14.09.2009 MR. RAJESH ANAND

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 Chapter No. 9

STEP 5 - ANNUAL TRAINING CALENDAR E&T

Annual Training Calendar (2011 – 12)

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 Chapter No. 9

STEP 5 - TRAINING ACTIVITY E&T

Case Study - Example of Training Activity

Skill Level Before Training

1S-2S at work place
4
Permanent Temporary Total
Sr.No Process
Operators Operators Operators 3
No material handling defect 2 Production as per norms

1 Machining 59 133 192 1

0
2 Painting - 15 15
To maintain basic condition
Loss capturing
of machine

3 LPDC 53 27 80

RequiredInprocess
Skill Level Actual Level
Inspection

4 Supporting - 20 20

5 Maintenance 25 - 25

TOTAL 137 195 332

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 Chapter No. 9

TRAINING ACTIVITY E&T

Training Schedule Training

Evaluation / Test

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 Chapter No. 9

TRAINING ACTIVITY E&T

Actual Practice on Training Topic at Work Station

Practice at Work Station

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 Chapter No. 9

TRAINING ACTIVITY E&T

Result - Skill Level After Training

Skill Level After Training

1S-2S at work place

4
3
No material handling defect 2 Production as per norms

1
0
To maintain basic condition
Loss capturing
of machine

Inprocess Inspection
Encouragement with appreciation
Required Skill Level Actual Level

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 Chapter No. 9

TRAINING ACTIVITY E&T

REVISED SKILL AND TRAINING NEEDS FOR PAINT SHOP PRE ASSESSMENT
AUDIT HOME WORK
At paint shop
Skill Evaluation
needs to be
done more
thoroughly

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 Chapter No. 9
STEP 6 - BASIC AND SKILL ENHANCEMENT TRAINING E&T
Basic Training to the New Operators, Maintenance Technician and Staff Training

Training Details

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 Chapter No. 9
BASIC AND SKILL ENHANCEMENT TRAINING E&T
Skill Enhancement Training to the Operators, Maintenance Technician and Staff
Training

Training Details

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 Chapter No. 9

NEW EMPLOYEE TRAINING PROGRAME E&T

Communication Training Plan

SAMAVES
H

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 Chapter No. 9
INDUCTION PROGRAM FOR NEW JOINESS E&T

Training Photos

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 Chapter No. 9

JH STEP 4 TRAINING E&T

Example of JH Step 4 Training
Know Why Manual
Methodology

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 Chapter No. 9

JH STEP 4 TRAINING E&T

Schedule Training
Training Category Duratio Trainee Jan -10 Feb-10
Topic Trainer
( Technical Training ) n (Hr.) ( Nos )
W1 W2 W3 W4 W1 W2 W3 W4
Fastners 2 P.K.Barnwal 332
Pnumatics 2 D.C.Joshi 332
M.D.Deshmuk
Hydraulics 2 332
h
Class Room Training Lubrication 1 D.S.Hatolkar 332
Drives 1 P.K.Barnwal 332
Electrical 1 K.O.Zanwar 332
Chip and
1 D.C.Joshi 332
Coolant
Fastners 2 P.K.Barnwal 332
Pnumatics 2 D.C.Joshi 332
M.D.Deshmuk
Hydraulics 2 332
h
Lubrication 1 D.S.Hatolkar 332
Technical Centre
Drives 1 P.K.Barnwal 332
Electrical 1 K.O.Zanwar 332

Chip and
1 D.C.Joshi 332
Coolant

Result of one batch

Out of 307 To upgrade the level of

employees – operators from B and C grade
66 got A+ Grade and to train new operators , We
166 got A Grade have planned JH step 4 training
75 got B Grade and activities , which has
explained in JH Pillar
Presentation.

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 Chapter No. 9

STEP 7 - MULTISKILL OF OPERATORS E&T

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 Chapter No. 9

KPI AND KAI LINKAGE E&T

PRE ASSESSMENT AUDIT HOME WORK

Key activity results to be added in presentation

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 Chapter No. 9

STEP 8 - INTANGIBLE BENEFITS E&T

For continuous Group consists

The
improvement of members Best Q C achievements
and problem either from Circles are shared
solving, Small same or cross participate in through In-
Group functional External House Quarterly
Activities are areas. Competitions. Newsletter.
carried out.

Results of Q.C.Circle activities & sharing through Quarterly News letter

12

10
10
9 9
8 8
8
Numbers

6
5 5

4
3

2
1 1
0
0
0
'06 - 07 '07 - 08 '08 - 09 '09 - 10 '10 - 11 Upto Dec.11
Year

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 Chapter No. 9

STEP 8 - RESULT - SKILL ENHANCEMENT E&T

Actual
Sr no Parameters Area UOM BM (06-07) Target Mar. 12
Dec. 11

Level 1 138 0 0

To enhance the Level 2 77 57 68

Skill & knowledge Number of Operators
of all Production Level 3 61 190 187
1 Operators from L1
to L4 Level 4 31 60 52

TOTAL 307 307 307

Level 1 0 -- --
To enhance the
Skill & knowledge Level 2 Number of Maintenance 05 0 0
2 of all Maintenance Fitter & Electrician
operators from L2 Level 3 09 0 02
to L4
Level 4 11 25 23

TOTAL 25 25 25

LEVEL 1 LEVEL 2 LEVEL 3 LEVEL 4

Know Basic but he cannot do Can Perform with guidance Can perform independently with self Can do with self confidence & teach to
confidence others also

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 Phenomena

10

0
1
2
3
4
5
6
7
8
9
'B
Ye M

9
ar
10
-1
1

5
Ap
r-1
1
M

Endurance L-6/3
3
ay
-1
1

0
Ju
n-
11

0
Ju
l-1
1
Phenomena Au

0
g-
11

10

0
1
2
3
4
5
6
7
8
9
Month
'B Se
0
Y M p-
ea 11

4
r 10
O
0
-1 ct
-1
MACHINE SHOP

1 1

2
A N
0

pr ov
-11 - 11
D
0

M ec

1
ay 'T -
-1 ar 11
1 g
BETTER

et
0

1
Ju ar
n- 1 2
0

11

1
Ju
l-1
1
A Phenomena

1
ug
-
10

0
1
2
3
4
5
6
7
8
9

11

Month
S 'B
M
LPDC SHOP

1
ep Ye
1

- 11 ar
10
-1
O 1 1
1

ct
-1 Ap
1 r-1
1
N
M
1

ov
0

- 11 ay
-1
1

Towards Excellence Through TPM

D
0
0

ec Ju
'T - n-
ar 11 11
g et
0
0

M Ju
BETTER

ar l-1
1 1
2
0

Au
0

g-
11
Month

Se
0
RESULT – DEFECT (PHENOMENON)

p-
11
O
PAINT SHOP

ct-
1
Page-

1
No
0

v-
11
0

De
'T c-
ar 11
g et
E&T

M
BETTER

ar
1
Chapter No. 9

2
29 of 32
0
 Phenomena

10
12

0
2
4
6
8
'B
Ye M
ar

11
10
-1
1

2
Ap
r-1
1
M

1
ay

Endurance L-6/3
-1
1

1
Ju
n-
11

1
Ju
l-1
1
Au

1
g-
11

Month
Se
Phenomena
p-
11 1
O

10
12

0
2
4
6
8
1

ct
'B -1
MACHINE SHOP

Ye M 1

6
ar N
0

10 ov
-1 - 11
1
D
0

1
Ap ec
r-1 'T -11
1 ar
g
M
et
0

1
BETTER

ay ar
-1 1
1 2
0

1
Ju
n-
11

1
Ju
l-1
1
Au Phenomena

1
g-
10
12

0
2
4
6
8

11

Month
'B
LPDC SHOP

Se M

1
p- Ye
2

11 ar
10
O 1 -1
ct
-1 1
1
0

Ap
N r-1
0
ov 1
- 11 M
0

ay
D
0

-1
ec 1
'T -

Towards Excellence Through TPM

11
0

ar
g et
Ju
n-
0

M
BETTER

11
ar
1 2
0

Ju
l-1
1
Au
0

g-
11
Month
RESULT – BREAKDOWN (OCCURANCES)

Se
0

p-
11
PAINT SHOP

O
0

ct-
1
Page-

1
No
0

v-
11
0

De
'T c-
ar 11
g et
E&T

M
BETTER

ar
1
Chapter No. 9

2
30 of 32
0
 Chapter No. 9

RESULT – ACCIDENTS E&T

4
4
Sustained
zero
Phenomena

3 Accidents

2
BETTER

0 0 0 0 0 0 0 0 0 0 0
0
'BM Year Apr-11 May- Jun-11 Jul-11 Aug- Sep- Oct-11 Nov- Dec- 'Target
10 - 11 11 11 11 11 11 Mar 12
Month

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 Chapter No. 9

FUTURE PLAN E&T

Year 2011
Sr Year-2012-13 Year-2013-14
Activity - 12
No
Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4

All Manuals to be updated with SOP

1
(Standard operating procedure).

Further Skill enhancement of Production

2
operators, and Maintenance operators.

Skill development for outsourced activities

3
to do in house.

4 Cell wise process updation

Visual control and Visual Management

5
improvements

6 Technical Centre updation

Activity Planed Activity In progress Activity Completed

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