Modern Manufacturing Worker Learning Model

Transcription

1 Modern Manufacturing Worker Learning Model How competency modeling and blended learning can meet training program requirements? 1

2 Manufacturing Training Landscape 600,000 manufacturing jobs have gone unfilled because of a shortage of skilled workers.* 83% of companies reported moderate-to-serious shortages in skilled production positions. The modern manufacturing company seeks to employ people with a range of skills rather than simple "button-pushers." *United States Department of Labor, Bureau of Labor Statistics, Unemployment rate data table 2

3 Higher skills are needed Manufacturing Employment by Skill Group, 2003 through 2010 Index 2003= High Low Mid Sources: Chmura Economics & Analytics and Current Population Survey. 3

4 Manufacturing Training Landscape Training departments only manage the 30% of the learning that is formal (70% is informal).* Manufacturers will need to build internal training programs that develop an inexperienced talent pool? Gen Yers will comprise 50% of the workplace in External requirements are demanding manufacturers show their workforce is competent in their job roles. *The Learning Alliance by Robert Brinkerhoff and Stephen Gill 4

5 Quality Standards Requirements Manufacturing is facing external pressures to validate their training programs, through both local, state, and federal programs. Building employee training programs that meet compliance standards is a challenge of many manufacturers. 5

6 ISO 9001, requirements Section e, Maintaining Training Records, sets the standards required by organizations to maintain records of education, training, skills and experience. The records referred to are records that provide: Evidence of the extent to which a person s abilities fulfill certain competence requirements Evidence of activities performed to specify, develop or verify the abilities of a person who is intended to fulfill certain competence requirements Such records will include: A personal development plan indicating the actions to be taken by the organization and the individual in the meeting competence requirements Records of actions taken Records of any measurement and verification of competence 6

7 Train an individual to the knowledge and skills requirements of the job (Body of Knowledge). Ensure an individual can perform tasks associated on the shop floor, in accordance with set standards. Certify the trainer in a standardized process for auditing an individual s performance. Maintain a record keeping system for all training activities. 7

8 WORKER VS. WORK Worker is the required competence an individual must possess in order to perform the work necessary for a particular job. Typically, this is defined through the development of a job description, which contains the knowledge, skills and abilities (KSAs) required of the job position. The process of competency modeling defines the required KSAs. Work is the act of performing the day-to-day tasks required by the job. The competencies prepare the individual for the work; however, work is more focused around the application of the KSAs to actual job duties. The development of work instructions are an example of documenting work. Assessing work involves performance of activities. 8

9 What model can be used to validate the body of knowledge for a worker and their continuing performance on the job. 9

10 Competency Modeling Competency is defined as: Areas of personal capability that enable people to perform successfully in their jobs by completing task effectively. A competency can comprised of knowledge, attitudes, skills, values, or personal values. Competency can be acquired through talent, experience, or training. In addition, competency comprises the specification of knowledge and skill and the application of that knowledge and skill to the standard of performance required in employment. 10

11 Competency Knowledge, skills, and abilities Performancebased knowledge and skills 11

12 Competency Job Descriptions Knowledge, skills, and abilities Pre-hire Assessments Work Instructions or SOPs Performancebased knowledge and skills Job Safety Analyses Job Aids 12

13 How does manufacturing train their workforce towards full competency? 13

14 Blended Learning Related instructional units or modules delivered through different learning modalities covering a major subject area. E-learning Instructor-led Training (ILT) Virtual Instructor-led Training (Virtual ILT) On-the-Job Training (OJT) Self-Instruction (books, videos) Job Performance Aids Media selection must be based on the learning context, the skills to be taught, the practicality of the situation and what theory indicates would be appropriate. Dick and Carey (1996) 14

15 Leverage Bloom s Taxonomy Knowledge: remembering of previously learned material. Understanding: ability to grasp the meaning of material. Application: ability to use learned material in new and concrete situations. Analysis: ability to break down material into its component parts so that its organizational structure may be understood. Synthesis: ability to put parts together to form a new whole. Evaluation: ability to judge the value of material for a given purpose. 15

16 Building a Competency-based Learning Plan 1 Define the job by identifying knowledge and skills that make up the worker. Machine Operator Competency Knowledge Knowledge of basic measuring devices used in the shop to ensure part quality. Skills Use of wide variety of precision measuring instruments as required. 16

17 Building a Competency-based Learning Plan 2 Map classes to build worker s knowledge base. Machine Operator Competency Knowledge Knowledge of basic measuring devices used in the shop to ensure part quality. Basic Measurement 110 Skills Use of wide variety of precision measuring instruments as required. 17

18 3 Building a Competency-based Build list of demonstrated skills to assess during structured OJT and ongoing employee evaluation. Learning Plan Utilizing part specification prints, Machine Operator Competency demonstrate proper measurements using a caliper. Knowledge Utilizing part specification prints, demonstrate proper measurements using a Knowledge of basic measuring micrometer. devices used in the shop to ensure Utilizing part specification prints, part quality. demonstrate proper measurements using a threaded ring gauge. Skills Use of wide variety of precision measuring instruments as required. 18

19 Building a Competency-based Learning Plan 4 Record all knowledge and skills requirements in learning management system. John Smith Machine Operator Curriculum Basic Measurement Online Demonstration of Measurement Skills Hands-On (Initial OJT) Demonstration of Measurement Skills Hands-On (Ongoing Evaluation) 19

20 How is manufacturing responding? From which of the following methods or techniques does your company identify and react to those gaps which impact your company? Method Informal feedback from supervisors or managers Percentage Formal performance appraisals Career development planning Feedback from training programs Formal competency modeling 20

21 How is manufacturing responding? From which of the following methods or techniques does your company identify and react to those gaps which impact your company? Method Percentage Informal feedback from supervisors or managers 81% Formal performance appraisals 57% Career development planning 31% Feedback from training programs 30% Formal competency modeling 17% 21

22 Questions and Discussion 4 22