CHƯƠNG TRINH đào tạo TÔNG THỂ CHO NHÀ máy THỰC PHẨM MATRIX TRAINING PROGRAM FOR FOOD FACTORY

Trai ning PLAN 2012
For
MENTOS
Perfetti Van Melle VN
CONCEPT
Content
MASTER TRAINING PLAN (2012)
THEORY COURSES
1
2
3
5
4
ON THE JOB TRAINING COURSES
7
BENEFITS FROM PROJECT
6
EVALUATION PLAN
TIME BUDGET ESTIMATION
8
TRAINER LIST
List trainer
List trainer
(Mentos)
(Mentos)
Leader of project
Leader of project
: Bui Viet Trung
: Bui Viet Trung
Supporting
Supporting

:
:


1. Safety: Nguyễn Đức Phúc
1. Safety: Nguyễn Đức Phúc


2. Hygiene: Phan Thị Phương
2. Hygiene: Phan Thị Phương


3. QC: Nguyễn T. Thủy Trúc
3. QC: Nguyễn T. Thủy Trúc


4. R&D: Lai Thị Châu Ngọc/Hữu Ý
4. R&D: Lai Thị Châu Ngọc/Hữu Ý


5. Engineer: Phan Thanh Toàn
5. Engineer: Phan Thanh Toàn


Phạm Hồng Tấn
Phạm Hồng Tấn


6. Pro.: Bùi Viết Trung
6. Pro.: Bùi Viết Trung

1
Step 1 – THEORY PART
Step 1 – THEORY PART
Step 2 – ON THE JOB TRAINING
Step 2 – ON THE JOB TRAINING
Step 3 – EVALUATE RESULT
Step 3 – 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


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 6 months training, Production
team will report performance base
on production efficiency report.

Totally we divide 2 parts:
-
1
st
: 28h/Packing operator &
24h /Process operator for theory
-
2
nd
: 16h/operator for
refreshment//every 6 mouths.

All operators must join all part of
the training courses base on
their working shift


All course will hold before shift 2
& after shift 1 with average
4h/week/group (including
training & refresh training
courses)

For Team Leaders &Supervisors:
- All courses will hold after shift 1
with average time/week.
- Total hours: 28h/staff

Training time must record for
overtime payment (for direct
labour)
TRAINING CONCEPT
2
Prepare by Bui Viet Trung


July- Sep 2012
July- Sep 2012
1)Training Needs
2) Project launching &
Material Preparation
Step 1: Theory Training
Basic theorecial Courses
Step 2: OJT Training
Step 3: Result Evaluation
Step 4: Refresh training
(Theory Training)

1) Basic Courses
2) Specific Courses
Current Time
Current Time
Remark:
Remark:
•
“
“
Basic theoretical courses” will be conducted by Trung & concerned trainer on
Basic theoretical courses” will be conducted by Trung & concerned trainer on
training room one time for 1 group base on shift working (process-coating & packing).
training room one time for 1 group base on shift working (process-coating & packing).
•
OJT will be conducted with concerned-trainer with each machine/process
OJT will be conducted with concerned-trainer with each machine/process
May - July 2012
May - July 2012
Sep – Nov 2012
Sep – Nov 2012
Nov – Dec 2012
Nov – Dec 2012
MASTER TRAINING PLAN FOR OPERATORS
(MENTOS AREA)
3
Juanuary - March 2013
Juanuary - March 2013
Prepare by Bui Viet TrungPrepare by Bui Viet Trung
MENTOS
Step 1: Theory Training

3) Basic Courses
4) Specific Courses
Step 2: OJT
Step 3: Result Evaluation
Current Time
Current Time
Remark:
Remark:


•
“
“
Basic Theorecial courses” and “Specific” will be conducted by Trung & relevant
Basic Theorecial courses” and “Specific” will be conducted by Trung & relevant
trainer base on shift working.
trainer base on shift working.
Sep – Nov 2012
Sep – Nov 2012
ON THE JOB TRAINING PLAN FOR TL& Sups
07
07
11
11
08
08
09
09
10
10

12
12
Nov – Dec 2012
Nov – Dec 2012


July– Sep 2012
July– Sep 2012
3
Prepare by Bui Viet Trung
Prepare by Bui Viet Trung
THEORY COURSES FOR OPERATOR
4
1.Safety
•
General safety
•
Safety online (Focus: Safety observation,
Unsafe action)
•
Hazard Identification & Risk Assessment for
individual operators.
•
Typical accidence
2. Hygiene
General requirements
Personal hygiene/ factory hygiene.
GMP/CCP awareness
3. Quality
Quality require (Export…).

Checking point
Operation require (AQL)
Frequent defects.
Prepare by Bui Viet Trung
THEORY COURSES FOR OPERATOR
4
4. Technology & Equipment
General requirements
Process technology awareness
Equipments awareness
5. 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
4
1.Safety
General safety
MIBB(Meeting-Inspection-Behavior Observation-
Behavior Feedback) Focus: Safety observation,
Unsafe action
HIRA (hazard Identification & Risk Assessment)
for individual opts.
2. Hygiene
General requirements
GMP /HACCP/Personal hygiene/Factory hygiene
Checking control.
3. 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
4.R&D
General requirements
Process technology

5. Technical & Equipment
General requirements
Process technical
Equipment awareness training.
6. 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 COURSES FOR OPERATOR
5
1.Safety
Safety on side (practical)
Safety observation, Un-safety
2. Quality
Quality require (Export, Home trade…)
Checking point (Start/Stop check list)
Operation requirements

3. Technology & Equipment
Process technology
Equipment awareness
4. Line Operating
5S (principle & practical), waste in Production.
Quick changeover
Starting up/shut down tasks
Operation control
(machine/quality/checking/record)
Checking point record
problem handing
Prepare by Bui Viet Trung
OJT COURSE FOR TL& SUPERVISOR
5
1.Safety
General safety.
MIBB(Meeting-Inspection-Behavior Observation-
Behavior Feedback) Focus: Safety observation,
Unsafe action
HIRA (hazard Identification & Risk Assessment)
for individual opts.
2. Hygiene
General requirements
GMP /HACCP/Personal hygiene/Factory hygiene
Checking control.
3. 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
OJT COURSE FOR TL& SUPERVISOR
5
4.R&D
General requirements
Process technology
5. Technical & Equipment
General requirements
Process technical
Equipment awareness training
6. 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
PD Manager
is on
oversea
training
6
EVALUATION CONCEPT
To evaluate base on 5 criterion skill:
1. Safety: No accident cause of people
2. Quality: Achieve product quality expected
3. Hygiene: Achieve 5S& GMP expected
4. Productivities: Achieve line performance expected
5. Cost: Reduce none quality cost
Prepare by Bui Viet Trung
14
PD Manager
is on
oversea
training
=> To evaluate exactly, all of relative depts have to
hold hand to set up the KPI for Evaluation.
6
ON THE JOB EVALUATE CONCEPT
No ID Name Machine
KPI
Standard
Actual
average

1 0001107 Nguyen Van Hung Cooking
Safety 0
Quality(NC) 0
Discipline 0
Hygiene N/A
Reliabilities 95%
2 0000488 Nguyen Van Anh Forming 1
Safety 0
Quality(NC) 0
Discipline 0
Hygiene N/A
Reliabilities 95%
15
Prepare by Bui Viet Trung
PD Manager
is on
oversea
training
6
BENEFITS FROM PROJECT
1. Improve quality
2. Improve opts performance
3. Improve manufacturing efficiency
4. To focus continuous improvement : reduce
changeover, reduce downtime.
5. Develop operating skill for Opts
6. Encourage team work spirit all among operators
16
Prepare by Bui Viet Trung
PD Manager

is on
oversea
training
7
BENEFITS FROM PROJECT
Improve line efficiency
OEE
Before
Training
After
Training
Bosch
14pcs-Machines
11pcs-Machines
17
Prepare by Bui Viet Trung
PD Manager
is on
oversea
training
7
BENEFITS FROM PROJECT
Standard
Before
Training
After
Training
Complaint
4/Mouth
NC

Rework 5%
Scrap
0.7%
Improve Quality at Mentos
18
Prepare by Bui Viet Trung
PD Manager
is on
oversea
training
Area
Total
cours
e
Group
Theorecal
Training
hours
OJT Training
hours
Mentos
212
(P7-
P12)
Process (19)
Coating (13)
Packing (45)
TL& Sups
(16)
28h/opt/year

28h/TL/year
24h/TL/year
28h/Sups/year
16h/opt/year
16h/TL/year
16h/TL/year
19h/Sups/year
Hours budget esti m a te
2012
19
Prepare by Bui Viet Trung
Document
Document
preparation
preparation
No.

Training
courses/
Issue to
consolidatio
n
Target
participants
Person
in charge Nov Dec Jan Feb MarApr
Ma
y Jun Jul Aug Sep Oct Nov
De
c

1 General safety
Theory Document
Sups/ TL/
Operators
Lâm/Phúc 31
OJT Document Minh/Phúc 15
Examination
Document
Phúc 31
2 Hyegine
Theory Document
Sups/
Team Leaders/
Operators
Lâm/Phương
(ISO)
10
OJT Document
Lâm/Phương
(ISO)
15
Examination
Document
Lâm/Phương
(ISO)
31
3 Quality
Theory Document
Sups/
Team Leaders/

Operators
Lâm/Trúc

15
OJT Document Lâm/Trúc 15
Examination
Document
Lâm/Trúc 10
4
Technology
& Equipments
Theory Document
Sups/
Team Leaders/
Operators
Tấn/Ý/Toàn 15
OJT Document Tấn/Ý/Toàn

15
Examination
Document
Tấn/Ý/Toàn 15
5 Operation
Theory Document
Sups/
Team Leaders/
Operators
Trung 29
OJT Document Trung 31
Examination

Document
Trung 29
6 Evaluation
Form for
evaluation
All



Prepare by Bui Viet Trung
Training Schedule
Training Schedule
T2 T3 T4 T5 T6 T7 CN
4 4 4 4 4 4 4 4
Note:
Note:
Average 4h/week/operator with:
Average 4h/week/operator with:
-
5’ warm up
5’ warm up
-
180’ Delivery information.
180’ Delivery information.
-
30’ meal time/15’ tea break.
30’ meal time/15’ tea break.
-
35’ Test.
35’ Test.

(Refreshment will be re-organizated after 6 months for
(Refreshment will be re-organizated after 6 months for
theory part (Safety/Hygiene/Quality/Operation)
theory part (Safety/Hygiene/Quality/Operation)
Prepare by Bui Viet Trung
Training requirment
Training requirment


Theory for Operators:
Theory for Operators:


- Presentation contents need delivery:
- Presentation contents need delivery:


1. What?
1. What?


2. How?
2. How?


3. Practically (pictures& real situation)
3. Practically (pictures& real situation)


4. Impact

4. Impact


- Exam content:
- Exam content:


1. Multichoice (10 questions)
1. Multichoice (10 questions)


2. Writing (2 questions)
2. Writing (2 questions)
Prepare by Bui Viet Trung
Training requirment
Training requirment


OJT
OJT
for Operators:
for Operators:
- OJT content need delivery:
- OJT content need delivery:


1. What?
1. What?

2. How?
2. How?


3. Practically (following small group)
3. Practically (following small group)


4. Impact
4. Impact
- Exam content:
- Exam content:


1. Writing (WI, SOP )
1. Writing (WI, SOP )


2. Following work result reported by direct
2. Following work result reported by direct
supervising(4weeks ).
supervising(4weeks ).
Prepare by Bui Viet Trung
Training requirment
Training requirment


Theory for TL& Sups:
Theory for TL& Sups:

- Presentation contents need delivery:
- Presentation contents need delivery:


1. What?
1. What?


2. How?
2. How?


3. Why?
3. Why?


4. Practically (pictures& real situation)
4. Practically (pictures& real situation)


5. Impact
5. Impact


- Exam content:
- Exam content:


1. Multichoice (10 questions)

1. Multichoice (10 questions)


2. Writing (3 questions)
2. Writing (3 questions)
Prepare by Bui Viet Trung
Training form
Training form


1. Internal training record sheet
1. Internal training record sheet


2. Course evaluation sheet
2. Course evaluation sheet
Prepare by Bui Viet Trung