Circle Leader

Jewellyn Reglos
Sub- Leader
Tobby Ilao
Circle Members
Dulce Interino Annie Rose Rabino
Marlyn Cabrera Aileen Garcia
Irish Fernandez Hermenia Cabingan
Donna Morris Mylene Catral
Mercy Caristea Ronamie De Guzman
 Problem Identification
During problem identification the circle identified sixteen different
problems and we’re able to trim it down to ten. Below is the final lists
of problems identified.

1. Training venue is not comprehensive.

2. Frequent conflict in training schedule and activities.
3. No reservation and monitoring of activities at Training room.
4. No hands-on training program for newly hired operators.
5. High lost time before qualification of newly hired operators.
6. No standard qualification for critical and non-critical processes
7. Inconsistent participants on different training programs.
8. No training evaluation to measure training effectiveness.
9. Insufficient training report
10. No PIC assigned to monitor and develop training program
 Problem Selection
To facilitate problem selection the group decided to subject identified problem into problem validation by
observing the actual situation, and analyze the extent of the problem. Problems are classified if
systematic problem solving is necessary or needs immediate action and attention.

Problem Observation Controllability Team Action

1. Training venue is not Different activities in training Controllable Immediate Action
comprehensive room conducted simultaneously
e.g., orientation, meetings, and
yellow board making.

2. Frequent conflict in No existing system of monitoring Controllable Immediate Action

training schedule and to check the activities at training
activities room; frequently causing conflict
in schedule.

3. No reservation and
monitoring of activities
at Training room

4. No hands on No training program for newly Controllable For further study

training program for hired operators inside clean-
newly hired operators. room.
 Problem Selection
Problem Observation Controllability Team Action

5. High loss time before No standard procedure on how Controllable For further study
qualification of newly to train and qualify newly hired
hired operators. operators after endorsement
inside clean-room

6. No standard qualifica- No standard regulations for Controllable For further study

tion for critical and non- qualification of critical and non-
critical process critical process.

7. Inconsistent partici- No training requisition system to Controllable Immediate Action

pants on different forecast and monitor anticipated
training programs. number of participants.

8. No training evaluation No training evaluation to monitor Controllable For further study

to measure training reactions of participants to
effectiveness training.
 Problem Selection
Problem Observation Controllability Team Action
9. Insufficient training report Insufficient training reports to Controllable Immediate Action
show actual accomplishment
and performance based on
target.

10. No PIC assigned to Based on existing training Controllable Immediate Action

develop and monitor organization no actual program
training program. is established to be improved
and monitored by PIC.
 Problem Selection
Based on problem validation there are six (6) problems that can be solved
immediately and four for further study. Below is the summary of problem
classified as for immediate action or for further study.

For Immediate Action For Further Study

1. Training venue is not comprehensive 1. No hands-on training program on

2. Conflict in training schedule and activities on newly hired operators
3. No training program/schedule for 2. High loss-time before qualification of
every requirement. newly hired operators.
4. Inconsistent participants in different 3. No standard qualification of critical and
training programs. non-critical process
5. Inconsistent report on training 4. No training evaluation to measure
accomplishment training effectiveness.
 For Immediate Action
To address all problems for immediate actions the agent of changes formulate alternatives to initiate
immediate solution. Below is the analysis and solution implemented by the group.

Problem1: Training venue is not comprehensive

Solution: Re-layout training venue to accommodate different training activities to avoid conflict in
schedule and conduct different activities simultaneously.

Before Implementation
66 ft.
19.9 ft.

Training Meeting Newly Hired Orientation

 For Immediate Action
After Implementation
27 ft. 27 ft. 11.9 ft.
19.9 ft.

Training Room 1 Training Room 2 Training Room 3/

Maximum Capacity = 50-60 Maximum Capacity = 50-60 Meeting Room
Maximum capacity = 16-20
 For Immediate Action
Problem 2: Conflict in training schedule and activities
Solution: Immediately implement a monitoring system that will organize schedule of training, meeting
and other activities.

PRODUCTION DIVISION
TRAINING GROUP
TRAINING PROSPECTUS (August 28 to September 3, 2006)

Training/ Orientation Subjects/ Target Participants

Title Outline
Date/Time Facilitator Objectives Venue Remarks
No. Position
Machine Safety Orientation Training -To know the safety precautions of every -Accident Report 50 /day - Operators Production
August 28 - Sept. 1, 2006 Engineers/Staff -Safety Policy Statement Training Room
machine used in the production line - Line Leaders
6:00pm – 8:00pm -Safety Benefits
- Learn the basic principle and application
of equipment and machine inside -Causes of Accidents
production - Safe and Unsafe Act
August 28 - Sept. 1, 2006 Inter-Division Training M. Zurbano - To Familiarize with the different functions of - Division Orientation 12 - Newly Hired Production
each Division & their roles in the Production of - Technical Training Engrs., Supv., Mgr Training Room
8:00 – 5:30
Spindle Motor - Line Tour & Observation
- Work Values
August 28 – 29, 2006 C. Llanes - To Train operators in Production rules & - Basic Math
Production Training - Newly Hired Production
M/S: 6am- 6pm Orientation regulation - Check-sheets 60
A. Rabino Operators Training Room
- To equip operators with the required & Datasheets
A. Garcia knowledge, skills, and attitudes before - Production
M. Caristea assigning in production. Rules & Reg.
- Tags and Labels
- Safety
August 28 & Sept. 1, 2006 LL Examination Donna Morris - Know the function and - Qualification paper 20 - Acting LL to Production
6am - 10am Marilyn Cabrera purpose of each processes on Certified SL Training Room
2pm - 6pm Irish Fernandez her assigned assembly
6pm - 8pm
August 29, 2006 Basic Mathematics Donna Morris - Know the proper application - Forms and Checksheets - Acting LL to Production
40 /day
Marilyn Cabrera and filling out of Checksheets Certified SL Training Room
August 30, 2006 Oven Datasheets / Tags & Datasheets
& Labels/
Forms and Checksheets
August 31, 2006 Machine Control
Checksheets / Master Motor
Datasheets
August 29, 31 & Sept. 5, 2006 Microsoft Excel Alma Manzanilla -To Know the different techniques & - Use & purpose of Microsoft 22/ - PSG Staff PSG – Office
Orientation command when using microsoft excel Excel per batch Extension
6pm - 8pm
- Learn the application of spreadsheet
solution
September 1, 2006 Basic Soldering G.P. Fajardo -To understand the principles of soldering -Solder Wetting 52 - Soldering Production
6pm - 8pm Technology technology -Roles of Flux Operators and Line Training Room
-To know the purpose and Function of -Flux Requirements Leaders
soldering elements -Influence of solder impurities
-To know the different types of soldering -Four Factors of soldering
equipments -Types of soldering Equipments

PREPARED BY: MR. LINO MAGTUBO CHECKED BY: MR. GENER FAJARDO APPROVED BY: MR. EMCE SALVAMANTE

DATE: 08-26-06 DATE: 08-26-06 DATE: 08-26-06

 PRODUCTION DIVISION
TRAINING SECTION

BARROWERS LOGSHEET
ROOMS & TIME RETURNED BY:
DATE NAME DIVISION DEPT/SEC. PURPOSE QTY. SIGNATURE
OTHERS FROM TO DATE

NOTE : NO RESERVATION NO ACCOMODATION !

 For Immediate Action
Problem 3: No Training programs for every requirements
Solution: Formulate a Training Chart for every level in the organization

ENGINEER
TRAINING CHART
 For Immediate Action
Problem 7: Inconsistent Participants on Different Training Programs
Solution: Formulate a Training Request and Confirmation form to forecast or monitor number of
participants.

PRODUCTION DIVISION
Training Section

TRAINING REQUEST AND CONFIRMATION FORM

TRAINING DURATION:
TITLE OF TRAINING/ DATE:
ORIENTATION: from __________to_________
TARGET PARTICIPANTS: TIME:
from __________to_________
C/R / MODEL/ASSY: VENUE:

OBJECTIVES:
NAME OF PARTICIPANTS:
1 6 11
2 7 12
3 8 13
4 9 14
5 10 15

Requested by: Reviewed by: Approved by:

(Training Supervisor) ( Training Manager)
TRAINING CLASSIFICATION:
On the Job Training In-house Off Site Overseas

Note: Please use separate sheet of paper if

the number of participants is more than 15
 For Immediate Action
Problem 9: Incomplete Training Accomplishment based on target and actual attainment
Solution: Formulate a Power point Presentation of accomplishment report

SAMPLE OF SAMPLE OF

ACCOMPLISHMENT REPORT ACOMMPLISHMENT REPORT

 For Immediate Action
Problem 10. : No PIC assigned to develop and monitor training program.
Solution: Assigned PIC for every training program
PRODUCTION DIVISION
TRAINING SECTION
ORGANIZATIONAL CHART
MR. EMCE SALVAMANTE
MANAGER

MR. GENER FAJARDO

SR. SUP ERVISOR
DOC UM ENTATION
M arib el Dip alac / M ariane B alid o y

JOB ORIENT AT ION (P HASE 2) SKILLS T RAINING & QUALIFICAT ION T ECHNICAL & LEADERSHIP T RAINING
Maricel Zurbano T oby Ilao / Jewellyn Reglos Lino Magt ubo

NEW LY HIR ED OP ER ATOR INTER DIV. TR AINING OP TR . P R OC ES S QUALIF IC ATION C R ITIC AL P R OC ES S QUALIF IC ATION
LEADER S HIP & TEC H. TR AINING QUALITY & P R ODUC TIVITY TR AINING
M ercy C aris t ea / Annie R o s e M ercy C aris t ea / M aricel Zurb ano R o namie Guzman VACANT
P R OGR AM P R OGR AM
R ab ino / Aileen Garcia / C armie (C uncurrent ) M ylene C at ral Dulce Int erino
Iris h F ernand ez / Do nna M o ris M arlyn C ab rera
Llanes

OUTS IDE AS S EM B LY
C LEANR OOM 1 C LEANR OOM 2 C LEANR OOM 3 C LEANR OOM 4 C LEANR OOM 5 C LEANR OOM 6 R o na m ie Guzm a n
M yra M a lba ta a n C he rry Lo te re nia Aida Ta rro na s Ale x Da ya g He rm e nia C a binga n M a ribe l Aro m in M yle ne C a tra l
(C o nc urre nt)

Vic ky P a gka liwa ga n

C o ra zo n De Le o n M a ric e l M a s a re do B e rna de tte Go ns a ga M a ris s a J unio
Liza C a ba s i M a ry Gra c e Vida l
Anna As unc io n J e nny Lluna r M a . J e m ina B um a ko d Lie zl B a lbe ro na
M a y B a la zo n J a s m in R a ga nda n P re c y Ta tlo ngha ri
P re c y C a na m a n Ne ne th Endrina l C a the rine Quindo za J o c e lyn Ga ba ta n
VA C A N T P o rtia Abdo n
R o c he lle Alva re z Wilm a M o nde ja r VA C A N T
C he ryl Lo pe ra
M a . C ris tina Vic to rino
VA C A N T
S he ryl Zulue ta
VA C A N T J a nic e S a c ra m e nto P ia Luzo n
S io ny C a c a o
J ulie t Alim puyo Ge ra ldine M o ne do Ado nis Alm a ida
Arlyn C ula ba t
J a que line P a s c ua Lily S o lim a Le a Arda le s
VA C A N T

Prepared By : Checked By : Approved By :

Name : Mr. Gener Fajardo Name : Mr. Emce Ss alvamante Name : Mr. Keita Has egawa
Pos ition : Sr. Supervis or Pos ition : Manager Pos ition : Divis ion Manager
 For Further Study
After addressing problems that requires immediate action, the circle re-evaluate the problems for further
study. After analyzing the remaining problems the group realized that three of them are closely related
with each other and can be re-stated as one - Low qualification rate of newly hired operators.

Problem Observation Controllability Team Action

1. No hands on No training program for newly Controllable For further study

training program for hired operators inside clean-
newly hired operators. room.

2. No standard qualifica- No standard regulations for Controllable For further study

tion for critical and non- qualification of critical and non-
critical process critical process.

3. High loss-time before No standard procedure on how Controllable For further study
qualification of newly to train and qualify newly hired
hired operators operators after endorsement
inside clean-room

4. No training evaluation No training evaluation to monitor Controllable For further study

to measure training reactions of participants to
effectiveness training.
 Problem Prioritization
To select the priority problems for further study. The group subject each problem in different criteria.
The
criteria used are urgency, quality, productivity, and problem muda.

Criteria

High loss-time before No training evaluation

Problem
qualification of newly hired to measure training
effectiveness
Urgency 70 30

Quality 50 50

Productivity 80 20

Impact to 90 10
members

TOTAL 290 110

Scale:
Insignificant 1- 3; Significant 4 - 6; Very significant 7-10
 PROBLEM STATEMENT

High loss-time before qualification

of newly hired operators in one
process at CR 5
 Understanding the Present Situation
Weekly Report for Newly Hired Operators (C/R # 5)
ww27-ww30 (Before Implementation)

80%

60%

40%

20%

0%
ww27 ww28 ww29 ww30
% Qualified 64% 70% 26% 59%
% Not Qualified 36% 30% 74% 41%
Time Losses Causing Low Qualification Rate
(Before Project Implementation)
40

20

0
1st Batch 2nd Batch 3rd Batch 4th Batch
(ww27) (ww28) (ww29) (ww30)
1. Waiting time before 3 5 36 8
process confirmation
2. On-going Qualification 0 3 22 2
3. Transfer to another 1 2 15 4
process
 Cause and Effect Analysis

MAN
MATERIAL
BUSY
PRODUCTION
SCHEDULE
LACK OF TRAINING LACKING OF TRAINERS
MATERIALS
INSUFFICIENT TRAINERS
HARD TO PULL-
NO AVAILABLE
OUT OPERATORS
SOP
FROM THE LINE

High loss-time during

qualification of newly
NO STANDARD
Hired operators
PROCEDURE AFTER
ENDORSEMENT TO FREQUENT
PRODUCTION LINE TRANSFERRING LACKING OF TRAINING ROOM
OF OPERATORS FOR QUALIFICATION
NO SPECIFIC
NO TRAINING PROCESS NO SPACE FOR NEWLY HIRED
PROGRAM FOR OPERATORS QUALIFICATION
NO PROCESS
NEWLY HIRED REQUISITION NO SPACE INSIDE THE
OPERATORS CONTROL CLEANROOM TO CONDUCT
QUALIFICATION
NO STANDARD
PROCEDURE TRAINING AREA IS NOT
INCLUDED FOR THE
METHOD C/R LAY-OUT
ENVIRONMENT
 Validation of Root-causes
Root-cause Observation Controllability Circle Decision

1. Insufficient Presently the number Controllable Not true root-

Trainers of trainer is 38 and the cause
total number of operators
is 5385. To compute
the actual requirement
the computation is based
on 1:140. Hence
MAN

5385/140 = 38

2. Hard to pull- Newly hired operators Inter-related True root-cause

out operators difficult to pull-out during
from the line. operation due to
constraint in production
schedule
 Validation of Root-causes
Root-cause Observation Controllability Circle Decision

3. No available During training of newly Inter-related True root-cause

MATERIAL

SOP hired operators, no SOP

available to discuss the
actual process. To access
trainee must go inside the
clean-room

4.No training
Presently training Controllable True root-cause
METHOD

program for
program for newly hired
newly hired
is up to PSG only. No
operators
training program
available for newly hired
inside clean-room.
 Validation of Root-causes
Root-cause Observation Controllability Circle Decision

5. No process Newly hired operators Inter-related True root-cause

MATERIAL

requisition control Has no confirm process

prior to endorsement at
production line, result
frequent transferring of
operators.

6.No standard It takes time before Controllable True root-cause

METHOD

procedure newly hired confirm to

for newly hired assigned process. The set
operators after schedule two weeks
endorsement to exceeds causing a lot of
production line loss-time.
 Validation of Root-causes
Root-cause Observation Controllability Circle Decision

7. Lacking of Many activities Un-controllable True root-cause

Training room for conducted in training
Qualification room can not
(R2D2) accommodate all training
ENVIRONMENT

requirements

8. Training area is Many activities Un-controllable True root-cause

not included in conducted in training
clean-room lay- room can not
out accommodate all training
requirements
 CIRCLE OBJECTIVE

TO REDUCE LOSS-TIME DURING

QUALIFICATION OF NEWLY HIRED
OPERATORS BY 15% BY THE END
OF WWK 33.
 Solution Formulation
Root-cause Solution Advantage Circle Decision

1. Hard to pull- Qualify operators before Processing time Go

out operators formal endorsement in wouldn’t be
MAN

from the line. the process interrupted only

because of
Process Exam
and Qualification

Provide SOP for Training Reading and

2. No available familiarization of Go
MATERIAL

SOP and Qualification

purposes. Close SOP can be done
coordination with DCG inside Training Rm,
and ISO Group. (before
endorsement)
 Solution Formulation
Root-cause Solution Advantage Circle Decision

3.No training Formulate Training Training inside Go

program for Program for Newly Hired cleanroom after
MATERIAL

newly hired operators after endorsement will be

operators endorsement in the line defined and serve
as guide to Trainers
during Training

4. No process Define operators Operators can Go

requisition control process prior to focus immediately
MATERIAL

endorsement on their assigned

through process since it
endorsement form was clearly
defined before
endorsements
 Solution Formulation
Root-cause Solution Advantage Circle Decision

Do major re-layout Space for Go

4. Lacking of
Training room for of the Training Qualification can
Qualification Room easily be identified
(R2D2)
ENVIRONMENT

5. Training area is Coordinate to IE Trainer can

not included in Group for the lay- conduct Go
clean-room lay- out qualification/
out examination inside
the cleanroom
Selection of Best Alternative Solution
Revision of existing Operators Skills Training and Qualification Regulation

OPERATORS SKILLS
TRAINING AND QUALIFICATI

Creation of Training Program for Newly Hired Operators upon endorsement

HANDS-ON
TRAINING PROGRAM
 Solution Implementation
Weekly Report for Newly Hired Operators (C/R # 5)
ww31-ww33 (After Implementation)

120%
100%
80%
60%
40%
20%
0%
ww31 ww32 ww33
% Qualified 92% 100% 100%
% Not Qualified 8% 0% 0%
Decrease in Time Losses Resulting to High Qualification Rate
(After Project Implementation)
60

50

40

30

20

10

0
5th Batch 6th Batch 7th Batch
TOTAL
(ww31) (ww32) (ww33)

1. Waiting tim e 1 0 0 53
before proces s
confirm ation
2. On-going 0 0 0 27
Qualification
3. Trans fer to 0 0 0 22
another proces s
Old Endorsement flow
Endorsement A
to Cleanroom

Get assigned process to Hands-on on her

assigned model 15 minutes
Engineer/Supervisor

8 hours
Issuance of OLTA
14 days to 1
month
Availabl No
e
process? Qualification of
Operators
Observation
Yes
on the line
Issuance of
SOP reading/ Process Qualification Badge
Observation
30 minutes

A
New Endorsement flow
A
Endorsement Form Issuance

Endorsement of Operators
Process Identification

Return Endorsement Form to

Return Endorsement to Training Section
Training Section

Designate operator for the Provide PSG-Administrative

required process and HRD with endorsement
copy

B
Copy operators' name to
Process Training Request
(PTRF)
Newly Hired Process
Monitoring
A
Achievement
Defined the Training Activities of Newly Hired operators in the
production line
Eliminated time losses caused by undefined Training Program
for Newly Hired Operator inside production

Future Plan
Achieve 100% qualification of newly hired operators for the
succeeding endorsements
Formulate specific continues training program for specific
critical process to be done on a quarterly basis
Create audio visual training/module for new and old operators
concentrating on proper handling and actual processing procedure