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Project Saraswati: Operator Training & Evaluation (Licensing) for World-Class Operational Excellence
Technical Paper
2013-01-2406
ISSN: 0148-7191, e-ISSN: 2688-3627
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English
Abstract
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:
- 1Induction Training
- 2Classroom Training
- 3On-Job Training
- 4Written Test and Evaluation
- 5Issue Operator License i.e. Certification
- 6Monitoring operator through Layered Process Audits (Effectiveness of Training Process)
- 7Renewal 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
- 1I (Informed) level - Knows the basic operation
- 2L (Learned) level - Can operate under guidance
- 3U (Understanding) level - Employee can operate without guidance
- 4O (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
Authors
Citation
Warade, V., Dalvi, G., and Sharma, R., "Project Saraswati: Operator Training & Evaluation (Licensing) for World-Class Operational Excellence," SAE Technical Paper 2013-01-2406, 2013, https://doi.org/10.4271/2013-01-2406.Also In
References
- Divgi-Warner Operator Training Procedure
- General Motors - Quality System Basics
- Warner's Borg Production System guideline For details vjwarade@divgi-warner.com
- ISO/TS 16949 Quality management systems - Particular requirements for the application of ISO 9001:2008 for automotive production and relevant service part organizations www.iso.org
- Liker , Jeffrey K. The Toyota way Esensi 2004