NEW OPERATOR AND MULTI-SKILL TRAINING PLAN

Aluminium Alloy Industries Sdn Bhd

Prepared by : P.Sashendran LPS Kaizen Center

1. How to be a good Trainer?

Skilled Operator Good Trainer Positive Mind Persistence Patience
Master The 4P

Process Knowledge

2. Supervisor's Role in Training

Create Operator Training Plan

Re-train for Non-Compliance

Train Operators

Check Training Effectiveness

3.1 New Operator Training Plan - Step1

H R T r a i n e r V e r i f i e dA p p r o v e d

O p e r a t o r N a m e : S t a t u s : C o n t r a c t / D a t e J o in e d :

D e p t / S h ift : FT or a ei ni gi nn g / A L ro e c a a l: r
E x e c u t iS v u e p e r v E i ns og ir n e e r / E x O e Dc H

N oP l a n ( 1 ( 2 ( 3 ( 4

( 5 ( 6 ( 7

( 8 )S k i l l E v a l u a t i o n ( 9 )T r a i n i n g P la n

P IC D ~a 6 7 D ~a y 21 D a~ y 1 STEP a1y :1 DHR will1y fill3 up 1 8 9D ~a yS2 t4 a )C o m p a n y R u l e s H R 1 Operator name, Status, 1 )S a f e t y & P P E R u l e S s u p e r v i s o r )3 S T r a i n i n g S Datev joined and which 1 ~ 3 u p e r is o r )O J T T r a i n i n g S u p Dept o and shift the e r v is r - S t a n d a r d i z e d W Operator r is assigned to. 2 ~ 1 8 S o u r pk e r v i s o - S O P S u p e r v is o r Inform onew operator of 22 ~~ 11 88 - I n s p e c t i o n S t a n Sd ua pr de r v i s r Company Rules. Sign off2 ~ 1 8 - Q u a lit y B u y - O f S u p e r v is o r f )N o n C o n f o r m a n c eSform vandd hand over the 3 ~ 4 uP pa er tr H i s on r l i n g a )O u t p u t S h e e t & C formrs andrt operator to the 5 ~ 6 Sh u e p c ek vh i es e o )W o r k O b s e r v a t i o n u p e r v i s o r S respective supervisor 1 9 S u p e r v is o r 2 0 2 1 f o r SS ku i pl l e U r vp i s o r

It e m

t u s

3.2 New Operator Training Plan - Step2

H R T r a i n e r V e r i f i e dA p p r o v e d

O p e r a t o r N a m e : S t a t u s : C o n t r a c t / D a t e J o in e d :

D e p t / S h ift : FT or a ei ni gi nn g / A L ro e c a a l: r
E x e c u t iS v u e p e r v E i ns og ir n e e r / E x O e Dc H

N oP l a n ( 1 )C o m

It e m p a n y & R u le s P P E

P IC H R

D a y

1 D ~a 6 y

7 D ~ a 1 2 1 D a ~ y 1 1 8 9 D ~ yS2 t 4 a t u s y 3 a 1 1 1 ~ 3

( 2 )S a f e t y

R u l e S su p e r v i s o r S u p e r v is o r

( 3 )3 S T r a i n i n g

S p e r v s o r STEP 2 : Safety &u PPE i rules - S t a n d a r d iz e W S o pk e r v i o r 2 ~ 1 8 - Supervisorsd willu rshows the employes the type - S P u p e is o r 2 ~ 1 8 ofn OPPE tusedt at SSdtheirrr vvwork area. - I s p e c i o n S a n ua pr de is o r 2 ~ 1 8 - Trainl ithe operators rhowr to use the PPE 2 properly - Q u a t y B u y - O f S u p e v is o f ~ 1 8 ( 5- )NTraino the r operators tron on rd l i nsafety aspects ~ of the o n C n f o m a n c eS uP pa er vH i s the g a 3 4 ( 6 )O workt area and Smachines. u t p u S h e e t & C h u e p c ek rs vh i es e rt o 5 ~ 6 ( 4 )O J T T r a i n i n g ( 7 )W o r k O b s e r v a t io n u p e r v is o r S S u p e r v is o r P la n f o r SS ku i pl l e U r vp i s o r 1 9 2 0 2 1 ( 8 )S k i l l E v a l u a t i o n ( 9 )T r a i n i n g

3.3 New Operator Training Plan - Step3

H R T r a i n e r V e r i f i e dA p p r o v e d

O p e r a t o r N a m e : S t a t u s : C o n t r a c t / D a t e J o in e d :

D e p t / S h ift : FT or a ei ni gi nn g / A L ro e c a a l: r
E x e c u t iS v u e p e r v E i ns og ir n e e r / E x O e Dc H

N oP l a n ( 1 )C o m

It e m p a n y & R u le s P P E

P IC H R

D a y

1 D ~a 6 y

7 D ~ a 1 2 1 D a ~ y 1 1 8 9 D ~ yS2 t 4 a t u s y 3 a 1 1 1 ~ 3

( 2 )S a f e t y

R u l e S su p e r v i s o r S u p e r v is o r S u p e r v is o r

( 3 )3 S T r a i n i n g ( 4 )O J T T r a i n i n g

- S t a n r iz d W S o u r pk e 2 ~ 1 8 STEP d3a : d3Se Trainingr v i s o r S O P S p r v o r 2 ~ 1 --- Fixedc locations uuaofdee allii ssmaterials, tools, PPE, 88 etc In s p e t i o n S t a n Sd pr r v o r 2 ~ 1 -- Wherey tou dispose e unwanted materials 2 ~ 1 8 Q u a lit B y - O f S u p f r v is o r ( 5 - Howo to oarrange uPmaterialsi n g )N o n C n f r m a n c eS pa er tr vH i s on rd l and tools a 3 ~ 4 ( 6 - Cleaning eof &work c area eand machines )O u t p u t S h e t C Sh u e p ek rs vh i es o rt 5 ~ 6 ( 7 )W o r k O b s e r v a t io n u p e r v is o r S S u p e r v is o r P la n f o r SS ku i pl l e U r vp i s o r 1 9 2 0 2 1 ( 8 )S k i l l E v a l u a t i o n ( 9 )T r a i n i n g

3.4 New Operator Training Plan - Step4

H R T r a i n e r V e r i f i e dA p p r o v e d STEP 4 : OJT Training O p e r a t o r N a m e D e p t / h ift : - Standardized: Work,nn SSOP,a l:Inspection Standard & S t a t u s : C o n t r a c t / FT or a ei ni gi g / A L ro e c a r D a t e Jo i e d : E x e c u t iS v u e p e r v E i ns og ir n e e r / E x O e Dc H Qualityn Buy-off training N oP a n I t e m IC D a y 1 ~ a 6 7 ~ a 1 21 D a~ y y y 3 - Test l operators daily P on whatD wasD learned 1 1 8 9D ~a yS2 t4 a t u s ( 1 )C o m a n y R u e s H 1 - Updatetp statusE lon l thep R7,r 13,o 19th day of training ( 2 )S a f e y & P P R u e S su e v is r 1

( 3 )3 S T r a i n i n g ( 4 )O J T T r a i n i n g - S t a n d a r d iz e d - S O P - In s p e c t io n - Q u a lit y ( 5 )N o n C o n f o r m

S u p e r v is o r S u p e r v is o r W S o u r pk e r v i s o r S u p e r v is o r S t a n Sd ua pr de r v i s o r a n c eS uP pa er tr vH i s on rd l i n g a

1 2 2 2 2 3

~ 3 ~ 1 8 ~ 1 8 ~ 1 8 ~ 1 8 ~ 4 6

B u y - O f S u p e r v is o r f

What is standardizeds vhwork? What is SOP?~ C Sh u e p c ek r i es o rt e 5 ( 7 What isb the vdifference ibetween both? )W o r k O s e r a t io S u p e r v s o r n 1 9
( 6 )O u t p u t S h e e t & ( 8 )S k i l l E v a l u a t i o n ( 9 )T r a i n i n g P la n S u p e r v is o r 2 0 2 1 f o r SS ku i pl l e U r vp i s o r

3.5 New Operator Training Plan - Step5

H R T r a in STEP 5 : Non Conformance Part Handlinge r V e r i f i e d A p p r o v e d O e r a t o r N a m e D e p t / h i : - Trainpa operatorst : wherenn S toLf troplace reject and repair parts S t t u s : C o n t r a c / FT or a ei ni gi g / A e c a a l: r E x e c t iS v u e p e r D a e Jo in e d : - Train toperators how to mark theseu partsv E i ns og ir n e e r / EH xO e Dc N la n It e m P IC D a 1 D ~a 7 D ~ a 1 21 y a ~ 1 1 8 9D - TrainoPoperators to report NC y part 6yissues D3toy the ~a yS2 t4 a t u s ( 1 )C o m p a y u s H 1 Supervisor n&atP Ralll eRtimesp R e r v i s o r ( 2 )S a f e t y P E u l e S su 1

( 3 )3 S T r a i n i n g ( 4 )O J T T r a i n i n g - S t a n d a r d iz e d - S O P - In s p e c t io n - Q u a lit y ( 5 )N o n ( 7 )W o r k C o n f o r m

S u p e r v is o r S u p e r v is o r W S o u r pk e r v i s o r S u p e r v is o r S t a n Sd ua pr de r v i s o r a n c eS uP pa er tr vH i s on rd l i n g a C Sh u e p c ek rs vh i es e rt o S u p e r v is o r

1 2 2 2 2 3 5

~ 3 ~ 1 8 ~ 1 8 ~ 1 8 ~ 1 8 ~ 4 ~ 6 1 9 2 0 2 1

B u y - O f fS u p e r v i s o r

( 6 )O u t p u t S h e e t & ( 8 )S k i l l E v a l u a t i o n ( 9 )T r a i n i n g P la n

O b s e r v a t io n u p e r v is o r S f o r SS ku i pl l e U r vp i s o r

3.6 New Operator Training Plan - Step6

H R T r a STEP 6 : Output sheet and checksheet i n e r V e r i f i e d A p p r o v e d O p a t o r N a m e : D e t / S h t : - Trainte ruoperators/ onpei howiA Lf toa fill up check sheet and S t a s : C o n t r a c t FT or a ni gi nn g / r ro e c a l: E x e c u t iS v u e p e r v E i ns og ir n e e r / E x O e Dc H D a t e J in e d : outputo sheet. N oP l n I m P IC D a y 1D - Stressa ont ereal timereporting.~ a 6y 7 D ~ a 1y 2 1 D3 a ~ y 1 1 8 9D ~a yS2 t4 a t u s ( 1 )C o p n y R le s H 1 - Check fmona how uEtheye areR e fillingr up the sheets. If they ( 2 )S a e t y & P P R u l S su p r v is o 1 Make Smistakes, re-traine until rthey fully understand. ( 3 )3 T r a in in g S u p r v is o 1 ~ 3

( 4 )O J T T r a i n i n g - S t a n d a r d iz e d - S O P - In s p e c t io n - Q u a lit y ( 5 )N o n ( 7 )W o r k C o n f o r m

S u p e r v is o r W S o u r pk e r v i s o r S u p e r v is o r S t a n Sd ua pr de r v i s o r a n c eS uP pa er tr vH i s on rd l i n g a C Sh u e p c ek rs vh i es e rt o S u p e r v is o r 2 2 2 2 3 5 ~ 1 8 ~ 1 8 ~ 1 8 ~ 1 8 ~ 4 ~ 6 1 9 2 0 2 1

B u y - O f fS u p e r v i s o r

( 6 )O u t p u t S h e e t & ( 8 )S k i l l E v a l u a t i o n ( 9 )T r a i n i n g P la n

O b s e r v a t io n u p e r v is o r S f o r SS ku i pl l e U r vp i s o r

3.7 Operator Work Observation

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How to do work observation ? Why is work observation important?

( H O r e l a S i g n a tu r e o f th e D e p a r tm e n t H e a d t h e t h e R o p e r a t o r o p e r a t o r a n d fo llo w fa ils s o n a ll t h e a b o v e m Ce o tn i og e r d t cu r l i a e t re i a h : i m n a t a b o v e Rm e e t n a i o n n ea d n c r i r t e - io a b : s e r v e r t i d e r t o s t o p p r o c e s s im m i m m e d i a t e l y a n d r e - t r a in o p e r a t o r o ff- lin a n y o n e o f t h e e t r a in r e - o b s e r v e s t ill fa il, o p e r a t o r h a s e d ia t e ly

3.8 New Operator Training Plan - Step7

H R T r a i n e r V e r i f i e dA p p r o v e d

O e a o r N a m e : D e p t / S h ift STEPt pa7 ru :s tWorka Observation:c a a l: S t : C o n t r c t / FT or a ei ni gi nn g / A L ro e r E x e t iS v u e p e r v s og ir n e r / E x O e Dc H a t e Jo in e d : - FillD up operator work observationc ureportE i nand e identify N oP a n I t e m P I a y 1 D ~a 6 7 D y Areas lwhere re-training C isD required. ~ a 1y 2 1 D3 a ~ y 1 1 8 9D ~a yS2 t4 a t u s

( 1 )C o m

p a n y &

R u le s

H R

1 1

( 2 )S a f e t y

P P E

R u l e S su p e r v i s o r S u p e r v is o r S u p e r v is o r W S o u r pk e r v i s o r S u p e r v is o r S t a n Sd ua pr de r v i s o r a n c eS uP pa er tr vH i s on rd l i n g a C Sh u e p c ek rs vh i es e rt o S u p e r v is o r 2 2 2 2 3 5 1

( 3 )3 S T r a i n i n g ( 4 )O J T T r a i n i n g - S t a n d a r d iz e d - S O P - In s p e c t io n - Q u a lit y ( 5 )N o n ( 7 )W o r k C o n f o r m

~ 3 ~ 1 8 ~ 1 8 ~ 1 8 ~ 1 8 ~ 4 ~ 6 1 9 2 0 2 1

B u y - O f fS u p e r v i s o r

( 6 )O u t p u t S h e e t & ( 8 )S k i l l E v a l u a t i o n ( 9 )T r a i n i n g P la n

O b s e r v a t io n u p e r v is o r S f o r SS ku i pl l e U r vp i s o r

3.9 Skill Evaluation for All Operators

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What is the difference between our current skill chart and the one shown here? Currently, How do we judge The operator skill level?

3.9.1 Skill Evaluation - Sample

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3.9.1 Skill Assessment - Sample

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N a m e S S A e s K c s n H A R I F & t g e : o f a l l t h e a s p e c t o f w o r k a n d a b l e t o t r a F L U D e a k I N T e s t i n g S U P i n n E R e w V I S w O o R r k e r s o n t r a j o b i n i n g

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3.10 New Operator Training Plan - Step8

H R T r a i n e r V e r i f i e dA p p r o v e d

p t o r N m e : D e p t / S STEPOS 8 et:ru aSkill atEvaluationg h/ Ai Lf tro e :c a a l: t a s : C o n r a c t / FT or a ei ni gi nn r E x u t iS v u e p D a Jo in d : - Fill upt eskille chart and assessmente cform e r v E i ns og ir n e e r / EH xO e Dc N oP l n I t e m IC D a y 1 D ~a 7 D a 1 21 D y 3 y 1 1 8 9 D ~ yS2 t 4 a t u s a - Identify a operator's low Pskill areas 6yfor ~ skilla ~uptraining

( 1 )C o m

p a n y &

R u le s

H R

1 1

( 2 )S a f e t y

P P E

R u l e S su p e r v i s o r S u p e r v is o r S u p e r v is o r W S o u r pk e r v i s o r S u p e r v is o r S t a n Sd ua pr de r v i s o r a n c eS uP pa er tr vH i s on rd l i n g a C Sh u e p c ek rs vh i es e rt o S u p e r v is o r 2 2 2 2 3 5 1

( 3 )3 S T r a i n i n g ( 4 )O J T T r a i n i n g - S t a n d a r d iz e d - S O P - In s p e c t io n - Q u a lit y ( 5 )N o n ( 7 )W o r k C o n f o r m

~ 3 ~ 1 8 ~ 1 8 ~ 1 8 ~ 1 8 ~ 4 ~ 6 1 9 2 0 2 1

B u y - O f fS u p e r v i s o r

( 6 )O u t p u t S h e e t & ( 8 )S k i l l E v a l u a t i o n ( 9 )T r a i n i n g P la n

O b s e r v a t io n u p e r v is o r S f o r SS ku i pl l e U r vp i s o r

3.11. Skill Improvement Plan

(1) Purpose is to upgrade operator skill level at least to 75%. Meaning the operator can do the job by himself without assistance from the supervisor. (2) An action plan to improve operators's skill level (3) 3 months planning (quarterly plan) (4) Refer to attached skill evaluation form and sample.

3.11 New Operator Training Plan - Step9

H R STEP 9 : Training plan for Skill Up T r a i n e r V e r i f i e d A p p r o v e d O p r a t o r N a m e : D e p t / S h ft : - Fill upa etskill o improvementAi Lplan S t u s : C n t r a c t / FT or a ei ni gi nn g / r ro e c a a l: E x e u t iS v u e p e r v E i ns n e e r / E H D a t Jo in e : - Submite Newd Operator Introductionc Traininggo irPlan,xO e Dc oP l a n I t m IC D y 1D 6 7 D ~ a 1 2 1 D a ~ y 1 1 8 9 ~ yS2 t 4 a y y 3 a Skill Nchart &e assesmentP and aSkill~ a ImprovementD Plan t u s ( 1 )C o m p a n y R u e s H R 1 To Engineer/Execl for verification and HOD for approval ( 2 )S a f e t y & P P E R u l e S s u p e r v i s o r 1 - Send3 a Scopyn to gHR dept pafters approval ( )3 T r a i in S u e r v i o r 1 ~ 3

( 4 )O J T T r a i n i n g - S t a n d a r d iz e d - S O P

S u p e r v is o r W S o u r pk e r v i s o r S u p e r v is o r 2 2 2 3 5 ~ 1 8 ~ 1 8 ~ 1 8 ~ 4 ~ 6 1 9 2 0 2 1

- In p e c t i o n S t a n Sd ua de r v o r 2 ~ 1 8 How does s engineer/execpr andi s HOD verify and approve? - Q u a lit y ( 5 )N o n ( 7 )W o r k B u y - O f fS u p e r v i s o r a n c eS uP pa er tr vH i s on rd l i n g a C Sh u e p c ek rs vh i es e rt o S u p e r v is o r C o n f o r m

( 6 )O u t p u t S h e e t & ( 8 )S k i l l E v a l u a t i o n ( 9 )T r a i n i n g P la n

O b s e r v a t io n u p e r v is o r S f o r SS ku i pl l e U r vp i s o r

3.12. Sample of filled up form

H R T r a in e r V e r if ie d A p p r o v e d

O p e r a t o r N a m e : B a h a dD u e r p t / S h i f t : C a s t i n g B S t a t u s : C o n t r a c t / F o r e Ti g a i n/ i L og c Aa lr e a : A l l o y W Th ee ee l C a s t a i n ig r r n n K d Iz w a n S a s h e D a t e J o i n 1 e / d6 /: 2 0 1 0 E x e c u t i v S e u p e r v i Es no gr i n e e r / E x H e Oc D

N oP la n ( 1 )C o m

It e m p a n y R u le s P P E R u le s

P IC H R

D a y 1 D a6 y 7 D a1 y2 1 3 D ~a y 81 9 D~ a 2 y S t a t u s ~ ~ 1 4 1 1 1 2 2 2 2 3 5 ~ 3 ~ 1 8 ~ 1 8 ~ 1 8 ~ 1 8 ~ 4 ~ 6 1 9 2 0 2 1

( 2 )S a f e t y &

S u p e r v is o r S u p e r v is o r S u p e r v is o r

( 3 )3 S T r a i n i n g ( 4 )O J T T r a i n i n g - S t a n d a r d iz e d - S O P - In s p e c t io n ( 5 )N o n ( 7 )W C o n fo r m - Q u a lit y B u y - O ff a n c e ( 6 )O u t p u t S h e e t & ( 8 )S k i l l E v a l u a t i o n ( 9 )T r a i n i n g P l a n W

o r kS u p e r v i s o r S u p e r v is o r

S t a n d a r Sd u p e r v i s o r S u p e r v is o r P a S r ut p H e a r nv d s l o n r g i i S u p e r v is o r S u p e r v is o r

C h e cS ku s p h e e r ev ti s o r

o r k O b s e r v a t io n

f o r S k i l S u pp e r v i s o r l U

4. Operator Multi-Skill Training Plan

(1) Purpose is to have operators capable to do different processes for the smooth flow of operations. Reduction in downtime due to operator absence, resignation, contract term over, etc. (2) For operators who have achieved min 75% skill level in their current process (3) Refer to Multi skill training plan form and sample
Current Process (Alloy Wheel Casting) Skill Level 75% Plan for Multi-Skill Training in (Engineering Casting)

4.1 Multi-Skill Training Plan Form

O P E R A T O R M U L T I S K IL L T R A IN IN G P L A N
T r a in e r V e rif ie d A p p r o v e d

O p e ra to r N a m e : D e p t / S h ift : S t a t u s : C o n t r a c t / F o r e i g nT r/ a L n icn a gl A r e a : i o D a t e J o in e d : S t a r t T r a in in g D a t e :

S u p e r v i s Eo nr g i n e e r / E x e Hc O D

N o P la n

It e m P P E R u le s

P IC

D a y 1

~D 6a y 7

~ D 1 a 2y 1 3 D a1 y8 1 9 ~

~D 2a 4y S t a t u s 1 1 2 2 2 2 3 5 ~ 3 ~ 1 8 ~ 1 8 ~ 1 8 ~ 1 8 ~ 4 ~ 6

(1 )S a fe t y &

S u p e r v is o r S u p e r v is o r S u p e r v is o r

(2 )3 S T r a in in g (3 )O J T T r a in in g - S t a n d a r d iz e d W - S O P - In s p e c t io n (4 )N o n (6 )W (7 (8 S t a n d a r d - Q u a lit y B u y - O ff C o n fo r m a n c e (5 )O u t p u t S h e e t & o r k

S u p e r v is o r S u p e r v is o r S u p e r v is o r S u p e r v is o r

P a r t SH u ap n e d r lvi n s go r i

Form is similar toS newv operator introduction plan. 9 u p e r is o r 1 ) S k i lHR ais not nthe initiator r ofs this form. l E v lu a t io S u p e v i o r 2 0 ) T r a i n i n g P l a n f o r S k i l l U Sp u p e r v i s o r 2 1 Supervisors will initiate this form
o r k O b s e r v a t io n

C h e c k s Sh u e p e e t r v i s o r