Training PLAN 2012 For Perfetti Van Melle VN MENTOS Content TRAINER LIST CONCEPT MASTER TRAINING PLAN (2012) THEORY COURSES ON THE JOB TRAINING COURSES EVALUATION PLAN BENEFITS FROM PROJECT TIME BUDGET ESTIMATION List trainer (Mentos) Leader of project: Bui Viet Trung Supporting: Safety: Nguyễn Đức Phúc Hygiene: Phan Thị Phương QC: Nguyễn T Thủy Trúc R&D: Lai Thị Châu Ngọc/Hữu Ý Engineer: Phan Thanh Toàn Phạm Hồng Tấn Pro.: Bùi Viết Trung Step – THEORY PART  Totally we divide parts: - 1st : 28h/Packing operator & 24h /Process operator for theory - 2nd : 16h/operator for refreshment//every mouths  All operators must join all part of the training courses base on their working shift  All course will hold before shift & after shift with average 4h/week/group (including training & refresh training courses)  For Team Leaders &Supervisors: - All courses will hold after shift with average time/week - Total hours: 28h/staff  Training time must record for overtime payment (for direct labour) TRAINING CONCEPT Step – ON THE JOB TRAINING Step – EVALUATE RESULT  After theory training course, Opts will join the OJT part (practice at production area) - Total hours: 16h/process operator 16h/packing operator 19h/TL& Sups  All course (safety/quality/operating /procedure…) will hold by supervisors/senior operators under supervising by Training Manager  During OJT, Training Manager/Trainer will follow up opt’s performance by weekly production report (line efficiency/discipline record/failure record/quality results)  The training report will summarized monthly by Manufacturing Training & Improving Manager to Management Prepare by Bui Viet Trung  Each part, Training & Improving Manager will summarized evaluation result and send to Management  Training & Improving Manager will hold meeting monthly between Management to inform/discuss all information relative to training tasks  After months training, Production team will report performance base on production efficiency report MASTER TRAINING PLAN FOR OPERATORS (MENTOS AREA) Current Time Remark: •“Basic theoretical courses” will be conducted by Trung & concerned trainer on training room one time for group base on shift working (process-coating & packing) •OJT will be conducted with concerned-trainer with each machine/process 1)Training Needs 2) Project launching & Material Preparation May - July 2012 Step 1: Theory Training July- Sep 2012 Basic theorecial Courses Step 2: OJT Training Sep – Nov 2012 Step 3: Result Evaluation Nov – Dec 2012 Step 4: Refresh training (Theory Training) 1) Basic Courses 2) Specific Courses Juanuary - March 2013 Prepare byby Bui Viet Trung Prepare Bui Viet Trung Current Time ON THE JOB TRAINING PLAN FOR TL& Sups 07 08 09 10 11 12 Remark: •“Basic Theorecial courses” and “Specific” will be conducted by Trung & relevant trainer base on shift working MENTOS Step 1: Theory Training July– Sep 2012 3) Basic Courses 4) Specific Courses Step 2: OJT Sep – Nov 2012 Step 3: Result Evaluation Nov – Dec 2012 Prepare by Bui Viet Trung Prepare by Bui Viet Trung THEORY COURSES FOR OPERATOR 1.Safety • General safety • Safety online (Focus: Safety observation, Unsafe action) • Hazard Identification & Risk Assessment for individual operators • Typical accidence Hygiene General requirements Personal hygiene/ factory hygiene GMP/CCP awareness Quality Quality require (Export…) Checking point Operation require (AQL) Frequent defects Prepare by Bui Viet Trung THEORY COURSES FOR OPERATOR Technology & Equipment General requirements Process technology awareness Equipments awareness Line Operating •5S (principle & practical) •OEE, waste in Production •Quick changeover •Basic tasks • Standard operating guide(machine/quality/record/checking) •Checking point record •Shut down tasks(machine/quality/record/checking) •problem handing Prepare by Bui Viet Trung THEORY COURSES FOR TL& SUPERVISOR 1.Safety General safety MIBB(Meeting-Inspection-Behavior ObservationBehavior Feedback) Focus: Safety observation, Unsafe action HIRA (hazard Identification & Risk Assessment) for individual opts Hygiene General requirements GMP /HACCP/Personal hygiene/Factory hygiene Checking control Quality •Quality require (Export/HT…) •Quality Checking point(Start/Stop check list) •Operation & checking require (AQL) •Some Frequent defects •Complain from customer Prepare by Bui Viet Trung THEORY COURSES FOR TL& SUPERVISOR 4.R&D General requirements Process technology Technical & Equipment General requirements Process technical Equipment awareness training Shift operating •5S (Principle & Practical) & Visual management •OEE awareness •Waste in Production •Quick change over •PDCA •Team operating management skills •HR management for production Prepare by Bui Viet Trung OJT COURSE FOR TL& SUPERVISOR 4.R&D General requirements Process technology Technical & Equipment General requirements Process technical Equipment awareness training Shift operating •5S (Principle & Practical) & Visual management technical •Waste in Production •OEE awareness •Quick change over •PDCA •Team operating management skills •HR management for production Prepare by Bui Viet Trung EVALUATION CONCEPT To evaluate base on criterion skill: Safety: No accident cause of people Quality: Achieve product quality expected Hygiene: Achieve 5S& GMP expected PD Manager is on oversea training Productivities: Achieve line performance expected Cost: Reduce none quality cost Prepare by Bui Viet Trung 14 No ID ON THE JOB EVALUATE CONCEPT Name Machine KPI Standard Safety PD Manager is on oversea training 0000488 Nguyen Van Anh Forming Hygiene N/A 95% 0 Discipline Hygiene N/A Reliabilities Cooking Quality(NC) Nguyen Van Hung Discipline Safety 0001107 Reliabilities Quality(NC) Actual average 95% => To evaluate exactly, all of relative depts have to hold hand to set up the KPI for Evaluation Prepare by Bui Viet Trung 15 BENEFITS FROM PROJECT Improve quality Improve opts performance Improve manufacturing efficiency To focus continuous improvement : reduce PD Manager is on oversea training changeover, reduce downtime Develop operating skill for Opts Encourage team work spirit all among operators Prepare by Bui Viet Trung 16 BENEFITS FROM PROJECT Improve line efficiency Before Training OEE After Training Bosch 14pcs-Machines 11pcs-Machines PD Manager is on oversea training Prepare by Bui Viet Trung 17 BENEFITS FROM PROJECT Improve Quality at Mentos Standard Complaint Before Training After Training 4/Mouth NC Rework Scrap PD Manager is on oversea training 5% 0.7% Prepare by Bui Viet Trung 18 Area Hours budget estimate 2012 Total Theorecal Mentos PD Manager is on oversea training cours e 212 (P7P12) Group Training hours Process (19) Coating (13) Packing (45) TL& Sups (16) 28h/opt/year 28h/TL/year 24h/TL/year 28h/Sups/year Prepare by Bui Viet Trung OJT Training hours 16h/opt/year 16h/TL/year 16h/TL/year 19h/Sups/year 19 Document preparation No   Training courses/ Issue to Target consolidatio participants n Theory Document General safety OJT Document Sups/ TL/ Operators Examination Document Hyegine OJT Document Examination Document Sups/ Team Leaders/ Operators Theory Document Quality OJT Document Examination Document Evaluation OJT Document Examination Document Form for evaluation Lâm/Phương (ISO) Lâm/Phương (ISO) Lâm/Phương (ISO) 15 31 10 15 31 15 Lâm/Trúc 15 Lâm/Trúc Theory Document Technology Sups/ & Equipments OJT Document Team Leaders/ Operators Examination Document Operation 31 Minh/Phúc Lâm/Trúc Sups/ Team Leaders/ Operators 10 Tấn/Ý/Toàn 15 Tấn/Ý/Toàn 15 Sups/ Team Leaders/ Operators Tấn/Ý/Toàn 15 Trung Theory Document Lâm/Phúc Phúc Theory Document Person Ma De in charge Nov Dec Jan Feb Mar Apr y Jun Jul Aug Sep Oct Nov c 29 Trung Trung All Prepare by Bui Viet Trung 31 29 Training Schedule T2 T3 T4 T5 T6 T7 4 4 4 4 CN Note: Average 4h/week/operator with: -5’ warm up -180’ Delivery information -30’ meal time/15’ tea break -35’ Test (Refreshment will be re-organizated after months for theory part (Safety/Hygiene/Quality/Operation) Prepare by Bui Viet Trung Training requirment Theory for Operators: - Presentation contents need delivery: What? How? Practically (pictures& real situation) Impact - Exam content: Multichoice (10 questions) Writing (2 questions) Prepare by Bui Viet Trung Training requirment OJT for Operators: - OJT content need delivery: What? How? Practically (following small group) Impact - Exam content: Writing (WI, SOP ) Following work result reported by direct supervising(4weeks ) Prepare by Bui Viet Trung Training requirment Theory for TL& Sups: - Presentation contents need delivery: What? How? Why? Practically (pictures& real situation) Impact - Exam content: Multichoice (10 questions) Writing (3 questions) Prepare by Bui Viet Trung Training form Internal training record sheet Course evaluation sheet Prepare by Bui Viet Trung Training form Exam sheet sample : Prepare by Bui Viet Trung Prepare by Bui Viet Trung ... to inform/discuss all information relative to training tasks  After months training, Production team will report performance base on production efficiency report 3 MASTER TRAINING PLAN FOR OPERATORS... (including training & refresh training courses)  For Team Leaders &Supervisors: - All courses will hold after shift with average time/week - Total hours: 28h/staff  Training time must record for overtime... Writing (3 questions) Prepare by Bui Viet Trung Training form Internal training record sheet Course evaluation sheet Prepare by Bui Viet Trung Training form Exam sheet sample : Prepare by Bui Viet