Pilot IMS Birmingham - Case Studies - Manufacturing: Surface Finishing

Surface Finishing

With the aggressive chemicals used for many finishing processes, close attention to health and safety is essential for both the systems that are established by management and in adherence to those systems by the workforce. These factors are comprehensively covered by a complete unit of the NVQ courses. However, we have often identified a general lack of understanding by operators of the dangers inherent in the operations carried on outside their own department, with dangerous conditions being unwittingly created. The wider coverage of the Health and Safety in the Workplace Certificate qualification is found to be of immense benefit to workers in these environments due to its all-embracing coverage of the responsibilities of others within the workplace.

Companies in this sector we have worked with include:

Adaptaflex Ltd / Cable Management Systems Ltd.

Anochrome / Wolverhampton Electroplating Ltd.

Birmingham Plating Ltd.

Interplas Coatings Ltd.

LBL Finishers Ltd.

Thomas H. Gee Ltd.

Example of Programme undertaken

Programme Details
Pilot was invited to run a range of NVQ courses for all operational staff working at the production plant, plus some bespoke training for supervisors and middle management. The NVQ programme was to include PMO, Warehousing, Distribution and Storage and Technical Services. The courses were to be followed up with health and safety courses for all employees.

Preparation
Enrolment was undertaken by Pilot staff throughout the production and warehousing areas. The relevant courses were identified for all participants and details of operational procedures were advised to Pilot's Assessors, who were to be based full time at the works. Three Assessors were assigned to the programme, with other trainers employed as appropriate.

Course Delivery
The Company produces a broad range of a wide variety of the most commonly required ancillary fixings and fittings.

The various processes involve the use of aggressive chemicals, naked flame, heat and lubricating oils. The Company pays close attention to health and safety, with a special hand-washing regime established in particular work areas.

Production operates a 3 shift system, with a permanent night shift. Access to the night shift for PILOT's Trainer/Assessors required attendance after 9.00 p.m. This was organised by arrangement with management, so that the participants were always aware of the dates for the Trainer/Assessor and were made available to work with their assessor for a short period at that time. Without this co-operation from operational management, the night shift operators would have been unable to complete their courses.

The health and safety programme was undertaken throughout the Company. This consisted of each individual completing a City and Guilds Certificated course based a written text for knowledge, workshops for practical exercises to reinforce the learning and a comprehensive knowledge test to confirm learning. To support this programme, the Company commissioned a DVD outlining the processes within the Company and the relevant health and safety measures which must be followed.

The two separate management training courses were undertaken, one featuring organisational aspects, the other concentrating on management skills for current and potential supervisors. Both courses were bespoke, the latter being built around the Team Leading course accredited by the Institute of Leadership and Management.

Outcomes
All courses were successfully completed, with the various suggestions for practical improvements to operational activities, generated as a function of the courses, raised with management. City and Guilds Certificates were issued to all the successful staff.

The use of the Health and Safety DVD assisted staff in passing the knowledge test and reinforced the importance of health and safety measures within the work environment. It also enables the Company to demonstrate that it has effectively addressed the legal requirements for the induction of new employees and sub-contractors regarding health and safety issues.

The management courses produced a practical blueprint for a new organisation structure to cover the three shift operation more effectively and 100% success on the certificated course.

PILOT was invited to roll out the NVQ programme to the office staff, to give them the same opportunity to gain a work-related qualification. Achievement of a relevant NVQ was established as an ongoing requirement for employees throughout the Company.

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