Browse Publications Technical Papers 2013-01-2406

Project Saraswati: Operator Training & Evaluation (Licensing) for World-Class Operational Excellence 2013-01-2406

In the pursuit of Manufacturing Excellence, DivgiWarner follows Quality System Basics which includes operator training as one of the key elements. Any manufacturing process consists of 5M's. Out of these 5M's, Machine, Material, Method, Measurement can be engineered to get the desired output. Required control is possible with the fifth ‘M’ i.e. Man by providing Standardized Training, resulting in Repeatability & Reproducibility from each process.
DivgiWarner has designed, developed and been practicing the unique process of Operator Training and Licensing. This paper describes the Operator Licensing process.
The process is divided into seven subsections inclusive of:
  1. 1
    Induction Training
  2. 2
    Classroom Training
  3. 3
    On-Job Training
  4. 4
    Written Test and Evaluation
  5. 5
    Issue Operator License i.e. Certification
  6. 6
    Monitoring operator through Layered Process Audits (Effectiveness of Training Process)
  7. 7
    Renewal of license
As an operator goes through this process, his/her skill level and competency increases with continuous practice.
Following are four levels on which skill up-gradation is done
  1. 1
    I (Informed) level - Knows the basic operation
  2. 2
    L (Learned) level - Can operate under guidance
  3. 3
    U (Understanding) level - Employee can operate without guidance
  4. 4
    O (Operate) level - Operator can guide others as a coach, able to solve quality and process issues
This process ensures common and structured training to all operators and to increase the number of multi skilled operators.
Objectives achieved through this system have been summarized as:
  • Zero unsafe incidence
  • Customer (Parts Per Million) PPM reduced by 64%
  • Increase in actual run rate and product quality which in turn increased OEE (Overall Equipment Efficiency) from 41% to 82.9%
  • Reduced operation lead time, to ensure 100% On Time Delivery to customers
  • This training increases operator involvement and enables him to give valuable suggestions for continuous improvement


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