Training Enhancement and Mentoring System (TEaMS)
Client: Metal Forming and Coating Manufacturer
Client Background
More operator turnover than ever before, with new operators coming from retail and hospitality industries. Loss of prior trainers due to retirement of many senior staff.
Challenge
Prior method of pairing new employees who had some manufacturing experience with experienced senior operators was no longer an option. One plant scrap event – due to lack of training for a new operator – resulted in $20,000 of scrapped product.
Solution
The Luminous Group utilized its TEaMS framework to capture essential job-specific knowledge for training new front-line workers. Three pilot jobs with higher turnover or training challenges were selected. Experienced supervisors and workers were identified as trainers, and a training coordinator for each job identified key knowledge packets and the optimal training sequesnce.
Implementation
We applied the What-How-Why model to ensure material was revisited at multiple stages, enhancing understanding and retention. The training checklists were also used to verify learning as training progressed. Trainers were also coached to mentor new employees, offering support and helping them integrate into the company culture.
Results
While initially there was some reluctance to try a new approach, TEaMS became the new training process in the plant.
- Faster training for new and operators switching jobs
- Higher process compliance and reduced scrap
- Increased retention rate of new employees
- Less variation in how employees are trained and training is consistent regardless of the trainer
Conclusion
One-time investment of $33,000. Estimated payback of $200,000 annually noted by:
- New employees are more productive in 4 weeks vs up to 12 weeks
- Improved compliance to job requirements and inspection criteria reduced scrap and customer complaints
- Less turnover of new hires, lessened the effort to find and select replacement workers
