To upgrade and improve machine operators and maintenance staff skills it is necessary to develop Training Process Guides (TPG) or they also called job aids.
TPG Training “Train the Trainer”
1. Objectives
- Get basic knowledge on the components of your manufacturing site’s Training Process Guides (TPGs)
- Understand the TPG process and your role and responsibilities on it.
- After completing this training, have a clear understanding on how to use the TPGs when training the Operators
2. TPG Components
2.1 Getting Started
2.2 Job Map
This section explains what are the major Duties and Tasks for the job classification
2.3 Module: Learning Objective
- Learning Objectives
Condition + Observable Behaviour + Standard
Example:
Given a knife jam, clear the jam and restart the Filler within 3 minutes
- Content
Text, Pictures, Discovery Exercises, OPLs, Visualearn. Explains “how” to perform a task
- Competency Checks
TPM Skill Level Matrix
2.4 Training Documentation/Records
- Training Documentation Summary (Hand-out): Outlines: Employee training plan, review meetings, progress on modules, qualification
- Skill Matrix (Hand-out)
- Evaluation of Training (Hand-out) Feedback sheet to evaluate effectiveness of the training material
TPG training process
3.2 Roles and Responsibilities
Roles |
Responsibilities |
TPG Coordinator | · Develop the material in conjunction with Area Supervisors
· Train the Trainers in TPG concepts · Audit execution of TPG training plans (based on records) · Evaluate effectiveness of training material (evaluation of training sheets) |
Area Supervisor | · Provide inputs to TPG Coordinator in order to develop the material
· Review TPGs (signature) · Train the Shift Supervisors whenever there is a change in the TPGs · Develop overall training plan for Operators |
Shift Supervisor | · Train Operators according to Training Plan or whenever we have a new hire
· Provide Training records (Training Documentation Summary, Skill Matrix) to Production Analyst · Evaluate effectiveness of Training on people (results on the floor) · Provide Training completion diploma to Operators |
Production Analyst | · Maintain training records in a central location
· Update training database. Keep Skill Matrix level records by Operator · Prepare formal diploma for Operators and provide them to Shift Supervisor |
Production & SQE Manager | · Provide priority based on business needs
· Provide feedback to update TPGs and approve them (signatures) |
3.3 TPG Document Control
Copy # | Resp. | Location | Forms | Special Comments |
Master | TPG Coordinator | TPG Coordinator Office | TPG-F-01 Master Review and Approval Form
TPG-F-02 Master and Copies Control Form |
Original information, signatures. All sections including discovery exercises and training material |
#1 | Shift Supervisors | Souproom Office | TPG-F-04 TPG Copies #1 and #2 Logsheet | All sections except discovery exercises and training material |
#2 | Shift Supervisors | Souproom Office | TPG-F-04 TPG Copies #1 and #2 Logsheet | All sections except discovery exercises and training material |
#3 | Area Supervisors | Area Supervisor Office | TPG-F-03 Feedback Form | All sections including discovery exercises and training material |
3.4 TPG Roll Out Roles and Responsibilities
Roles | Responsibilities |
Area Supervisor | · Train Operators according to Training Plan
· Provide Training records (Training Documentation Summary, Skill Matrix) to Production Analyst |
Shift Supervisor | · Train Operators according to Training Plan or whenever we have a new hire
· Provide Training records (Training Documentation Summary, Skill Matrix) to Production Analyst · Evaluate effectiveness of Training on people (results on the floor) · Provide Training completion diploma to Operators |
Production Analyst | · Coordinate the Training Plan outlining trainees in the Production Schedule
· Maintain training records in a central location · Update training database. Keep Skill Matrix level records by Operator · Keep KPI updated and communicate them to the group |
Production Manager | · Ensure resources are available to complete the training plan
· Define priorities according to progress and restrictions found throughout the process |