Example of Programme undertaken

Programme Details
The Company operates as a first line supplier within the automotive sector. It thus comes under severe cost and time pressure from its few, large and commercially powerful customers. It works a three shift system for the injection moulding and a single day shift for assembly work. There is a strong culture of giving exceptional service and working closely with the customers to develop and progress their new models, leading to frequent overtime and weekend working.

With the tight margins imposed by the automotive manufacturers on their suppliers, wage rates were relatively low for the area and work content. These factors created a steady turnover of operational staff and a reliance on agencies to provide immediate cover for absences. This puts a strain on operator training and increases the risk of loss of quality.

In this pressured work situation, PILOT was invited to deliver NVQs throughout the workforce, to confirm their competence to perform their operations to Company requirements and nationally accepted standards. The range of NVQs to be delivered comprised:

Performing Manufacturing Operations (PMO) Level 2,
Warehousing, Distribution and Storage Level 2,
Technical Services Level 2
Technical Supervision and Business Improvement Techniques (BIT) at Level 3.

A series of Workshops for selected managers was also run to cover management skills.

Preparation
Two Assessors well experienced in quality and engineering production were assigned to the programme full time, to deliver the PMO course. Three further Trainer/Assessors were allocated to deliver the other courses on a one day per week basis, commencing March 2004. The courses received support funding made available through Pilot's Franchise Partnership with a local Further Education College.

Course Delivery
The common problems associated with shift working and continuous production lines - difficult of access to the operational staff - were quickly evident. The problem is always compounded at night, when a skeleton staffing level is maintained, leaving very little opportunity for the Trainer/Assessor to work with the course participants. The two main Trainer/Assessors managed to mitigate the effects of the shift pattern by rescheduling their days and their programme of meeting with the individual participants. This involved splitting some days into morning and evening working. The workforce responded well to this arrangement, which was supported by the operations managers, who worked with the schedules to organise cover for the operators for when they were scheduled to be away from their workstations.

Outcomes
Flexibility proved to be the key to the completion of the course for all the operators, with all those in full time employment successfully completing their course and gaining their qualification. As is often the case, the effect on some participants was profound, with operators who had originally shown little interest in their work transformed into confident staff, performing reliably and looking for advancement within the organisation.

The PMO course was followed by a fully certificated, Health and Safety course to be undertaken throughout the Company. This was supported by a specially commissioned induction video which we produced to cover all the essential health and safety features that need to be taught to new employees and contractors working at the site. This video was shown to all existing staff and operated on a loop in the entrance foyer for all visitors. In this way, every aspect of the safety requirements was put across fully and effectively and the frequent and untimely interruption of managers was avoided.

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