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, doi:10.4271/2013-01-2406.
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: 1Induction Training2Classroom Training3On-Job Training4Written Test and Evaluation5Issue Operator License i.e. Certification6Monitoring operator through Layered Process Audits (Effectiveness of Training Process)7Renewal of licenseAs 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 operation2L (Learned) level - Can operate under guidance3U (Understanding) level - Employee can operate without guidance4O (Operate) level - Operator can guide others as a coach, able to solve quality and process issuesThis 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 incidenceCustomer (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 customersThis training increases operator involvement and enables him to give valuable suggestions for continuous improvement