The following gives a summary of the type of Training Material that CTS can develop, however, these should not be viewed as the only material that we can develop as we are constantly looking for new and innovative ways of developing and presenting Training Material. All of our material is customised to suit your needs and operational requirements.
CTS has vast experience of developing material for a broad range of industries as can be seen from the list of existing customers and within the business itself and its employees we have a vast amount of industry specific knowledge and skills to draw upon.
Also with reference to our list of existing clients, confidentiality is of utmost importance to CTS and as such confidentiality agreements would be signed prior to commencing any material development.
- Machine Specific:
Our training material is machine-specific based, which means it is designed specifically on your machines to suit your needs. This material can either be unit standard aligned or “fit for purpose” meaning that it is specifically designed to meet your specific business needs and your strategic objectives.
The training material can be developed as an integrated learner training guide and as an assessment tool, therefore removing the amount of paperwork required for the assessment process. As CTS has many years of On-Site Training we have found that the integrated training module works well for both the learner and assessor.
- Photograph (picture) Based:
Because of our experience in On-Site training and given the general educational levels of many of our factories all our material is photograph based and aimed at operator level, however this can easily be adapted to suit the needs of qualified artisans.
Process Machine Operational Modules Overview
Process Machine Operational Modules that are developed assist manufacturers to improve their plants’ operational performance, brand integrity and manufacturing responsiveness. It does so through consistent execution of unit/line operations, improved reliability and repeatability of equipment set-up.
With these Machine Operational Modules, you can:
- Use them to assess the competency levels of existing operators;
- Train new employees on the function and operation of machines;
- Remove the “word of mouth” training approach that has led to many bad habits and safety implications;
- Upon training and subsequent assessment it holds the operator accountable for any operational deviations;
- Improve brand integrity through consistent execution of unit/line operations and raw material usage;
- Improve time-to-volume and responsiveness through improved reliability and repeatability of equipment set-up and operations;
- Immediately detect deviations from specifications.
Autonomous Maintenance Modules Overview
As part of the CTS First Line Maintenance Program, this program is designed to provide foundational engineering theory and underpinning knowledge to machine operators/setters that will enable them to move from being “push-button” operators to Technical Operators; a Technical Operator being an individual able to assist an artisan on a basic maintenance level; eg: minor adjustments, lubrication, fault diagnoses, assisting with general maintenance, etc.
Part of the approach of the First Line Maintenance Program is the practical application and implementation of the Operational and First Line Maintenance training onto the specific machines through facilitation and practical demonstration.
This training program is complemented through the development of the First Line Maintenance training modules. These modules included the following aspects:
- Safety and Lock-Out Procedures;
- Machine In-Feed;
- Machine Out-Feed;
- Perform Daily Cleaning;
- Perform Component Change-Over;
- Perform Quality Control Tasks;
- Perform Lubrication;
- Perform Condition Monitoring.
The actual tasks, included in the modules, are operator-based and based on the theories of both Total Productive Maintenance and World Class Manufacturing, therefore alleviating valuable artisan time that is used to perform these tasks and ultimately made the responsibility of the machine operator, which in general terms is:
- Perform Cleaning;
- Perform Inspection;
- Perform Lubrication;
- Performing Changes-Over;
- Perform Minor Adjusts.
Additional Training Material
Standard Operating Procedures (SOP):
A Standard Operating Procedure is a set of instructions having the force of a directive, covering those features of operations that lend themselves to a definite or standardised procedure without loss of effectiveness. Standard Operating Policies and Procedures can be effective catalysts to drive performance improvement and improving organisational results. Every good quality system is based on its standard operating procedures (SOPs). Generally four Standard Operating Procedures would be developed; these include:
- Start-Up Procedure;
- Shut-Down Procedure;
- Change-Over Procedure;
- Safety Procedure (see below);
These would be laminated and located at the machines in clear view for all to see.
Safe Working Procedures (SWP):
Experience has shown that if safety is incorporated into the first three procedures they tend to be generic and lack detail, we believe that this is unacceptable, therefore we propose the development of stand-alone Safe Working Procedures (SWP), these would be machine specific and as a result would give the operator accurate safety details that are relevant to that specific piece of machinery. In order to be able to develop these we would utilise the following documentation that is currently in use at your site.
As can be seen the model above shows that each document has an impact on the other and as such by incorporating them into the SWP will ensure that all risks to person, machine and environment have covered and preventative measures established.
Autonomous Maintenance Checklists:
The Autonomous Maintenance (AM) standards are set in the form of checklists describing the tasks to be performed by operators that have completed the First Line Maintenance Program. These checks generally incorporate:
- Tools to be used in performing the task;
- Standard time to be taken to perform the task;
- Frequency of performing the task (daily, weekly, etc.).
Assessment Tools, Checklists & Knowledge Tests:
If the Machine Operational Modules and First Line Maintenance Modules are unit standard aligned or customer specific, then all assessment instruments, tools, checklists and knowledge can be developed subject to your requirements.
Competency matrices can be developed for several levels of employees; including, operator, team leader, artisan etc. These matrices are designed to show the technical skills and soft skills competencies required to perform the various positions within a business.
These are generally developed against job profile then by individual giving a visual overview of any training needs required by the various employees. These matrices can be used as a valuable tool when completing the Workplace Skills Plans (WSP’s) and subsequent Implementation Reports. By having a comprehensive matrix of all the competencies required by the organisation allows for more accurate training budgets to be established and controlled.
Problem Solving Material:
CTS can also develop training material targeting specific problems that organisations experience. This training is invaluable if reoccurring problems are occurring as controlled training sessions can be conducted were by the problem and solutions are discussed and competency in resolving the problem can be ascertained, thereby eliminating reoccurring problems by having the knowledge and skills transferred to all affected parties.
Interactive Training Material:
CTS can also provide interactive training material that makes use of both animation and video footage of your specific machines and operations, which allows for all training to be conducted in a classroom environment, removing the problem of noise levels found in most factories. By using video and animation, it can be used as an aid to ascertain the learner’s competency levels in a simulated environment before even going onto the actual machines, thus eliminating valuable production time generally caused by machine stoppages during training. This is seen to be a valuable tool especially when dealing with health and safety aspects.
Work Instructions (W.I. 1 -21):
Work Instruction development applies to one or more machines or machine processes. It includes supplier or agent details and can also be cross-referenced to the supplier’s manuals where appropriate. The level of detail included in the manual will be determined by the need for training or future reference which is company specific. Work Instruction manuals cover a wide variety of information ranging from the Background Theory of the machine to problem solving.
Total Productive Maintenance Modules are machine specific training modules that are based around the Autonomous Maintenance pillar in the TPM program. These modules incorporate operational tasks, autonomous maintenance tasks, quality management, changeover tasks and fault finding tasks. These modules serve as an efficient platform to introduce and maintain TPM standards in the workplace.