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Competency Gap

VIEWS: 18 PAGES: 15

									Efeso - Client name




                                           Machine                           1                                                                     Line                          xy

                                                                                                                             MATERIAL                                                MAIN OPERATIONS                                                          QUALITY                                                          SET-UP/ADJUSTMEN
                                                         OPERATIONS (level B)
                                                                                                                              (level C)                                                   (level C)                                                           (level C)                                                             (level C)

                                                           Skill (level D)




                                                                                                                                                                                                                                                   Material Quality Control
                                                                                              Materials Identification




                                                                                                                                                   Material Loading / Un-




                                                                                                                                                                                                                                                                                                                                                                                         Cylinder Replacement
                                                                                                                                                                                                                             Machine Lubrication




                                                                                                                                                                                                                                                                                                                                            Adjustment Material
                                                                                                                                Stock Management




                                                                                                                                                                                                                                                                                  PF Quality Control
                                                                                                                                                                                 Machine Start-Up




                                                                                                                                                                                                                                                                                                           Cycle Parameter
                                                                                                                                                                                                         Machine Reset




                                                                                                                                                                                                                                                                                                                             Adjustment /




                                                                                                                                                                                                                                                                                                                                                                      Die Change
                                                                                                                                                                                                                                                                                                                             Component


                                                                                                                                                                                                                                                                                                                                            Positioning
                                                                                                                                                                                                                                                   at entry




                                                                                                                                                                                                                                                                                                           Control
                                                                                                                                                   loading




                                                                                                                                                                                                                             Points
                                           Operator
                                                                           start                                         2
                                           John Gordon                   current                                         3
                                                                          target       1
                                                                           start
                                           Jeff Goldberg                 current
                                                                          target
                                                                           start
                                           Steve Fults                   current
                                                                          target
                                                                           start
                                           Anthony
                                                                         current
                                           Watkins
                                                                          target
                                                                           start
                                           Tim Anderson                  current
                                                                          target

                                                                  Start Average:                     0                               0                      0                         0                      0                      0                        0                         0                         0                0                0                     0                     0
                                                                Current Average:                     0                               0                      0                         0                      0                      0                        0                         0                         0                0                0                     0                     0
                                                                         Target:                     0                               0                      0                         0                      0                      0                        0                         0                         0                0                0                     0                     0
                                                 Start GAP of Skill Level D                          0                           0                          0                         0                   0                         0                        0                         0                         0                0              0                       0                     0
                                                 Start GAP of Skill Level C                                                     0.0                                                                      0.0                                                                  0                                                                 0.0
                                             Current GAP of Skill Level D                            0                           0                          0                         0                   0                         0                        0                         0                         0                0              0                       0                     0
                                             Current GAP of Skill Level C                                                       0.0                                                                      0.0                                                                  0                                                                 0.0

                                                                 Level of Knowledge
                                                               Be able to teach                                                    5
                                                     Be able to do it in non std conditions                                        4
                                                      Be able to do it in std conditions                                           3
                                                               Know the theory                                                     2
                                                           Do not know the theory                                                  1


                                                                           Actual           Target
                                           Cycle
                                           Parameter                                                                                                                                                                                                                              SET-UP ADJUSTMENT LOSS
                                           Control                                  4%                         4%
                                           Adjustment /                                                                                                                                                                                                                                                                                                                            Cylinder Replacement
                                           Component                                4%                         4%                                                                                   35%                                                                                                                                                                            Die Change
                                           Adjustment                                                                                                                                                                                                                                                                                                                              Adjustment Material Positioning
                                           Material                                                                                                                                                                                                                                                                                                                                Adjustment / Component
                                           Positioning                               7%                        7%                                                                                   30%
                                                                                                                                                                                                                                                                                                                                                                                   Cycle Parameter Control
                                           Die Change                               10%                        5%
                                           Cylinder Replacement                      4%                        4%                                                                                   25%


                                                                                                                                                                                                    20%




                                                                                                                                                                            Loss %
                                                                                                                                                                                                    15%


                                                                                                                                                                                                    10%


                                                                                                                                                                                                        5%


                                                                                                                                                                                                        0%
                                                                                                                                                                                                                                                                              Actual                                                                                                                            Target




                                                                                                                               START                                   1                            2                    3                    4                          5                             6                7 TARGET
                                                                                           Before                                10%
                                                                                           Follow-up                                                           9%                           8%               11%                        6%                       4%                            5%                  3%
                                                                                           Target                                                                                                                                                                                                                                   5%




                                                                                                                                                   Die Change loss reduction follow up

                                                                          12%



                                                                          10%



                                                                            8%



                                                                            6%



                                                                            4%



                                                                            2%



                                                                            0%
                                                                                     START                                                 1                                2                                            3                           4                                                 5                        6                                 7                   TARGET




                                                                          Before            TargetAfter Training
                                           Cycle
                                           Parameter
                                           Control               4%                           4%                                4%
                                           Adjustment /
                                           Component             4%                           4%                                4%
                                           Adjustment
                                           Material
                                           Positioning           7%                           7%                                7%
                                           Die Change           10%                           5%                                2%
                                           Cylinder Replacement 4%                            4%                                4%




                                                                                                                               SET-UP ADJUSTMENT LOSS

                                                                                                                                                                                                                                                                                  Cylinder Replacement
                                                     35%                                                                                                                                                                                                                          Die Change
                                                                                                                                                                                                                                                                                  Adjustment Material Positioning
                                                     30%                                                                                                                                                                                                                          Adjustment / Component
                                                                                                                                                                                                                                                                                  Cycle Parameter Control

                                                     25%

                                                     20%
                                            Loss %




                                                     15%

                                                     10%

                                                     5%

                                                     0%
                                                                                 Before                                                                                                                  Target                                                                                                       After Training




a1aea25d-721c-4226-a7fe-e849ab945962.xls                                                                                                                                                                                                         Efeso © 2003
                                                                                                                                                                                                                                                                                                                                                                                                                         1 of 15
Skill Identification                                                                                                                                                                                                                           Printed 5/27/2012
Efeso - Client name




                                           Mach:                             1                                                                     Line:                             xy

                                                                                                                         MATERIAL                                                      MAIN OPERATIONS                                                              QUALITY                                                                SET-UP/ADJUSTMEN
                                                                  AREA (level B)
                                                                                                                          (level C)                                                         (level C)                                                               (level C)                                                                   (level C)

                                                          Skill (level D):




                                                                                                                                                                                                                                                         Material Quality Control
                                                                                              Materials Identification




                                                                                                                                                   Material Loading / Un-




                                                                                                                                                                                                                                                                                                                                                                                                      Cylinder Replacement
                                                                                                                                                                                                                                 Machine Lubrication




                                                                                                                                                                                                                                                                                                                                                        Adjustment Material
                                                                                                                            Stock Management




                                                                                                                                                                                                                                                                                          PF Quality Control
                                                                                                                                                                                     Machine Start-Up




                                                                                                                                                                                                                                                                                                                       Cycle Parameter
                                                                                                                                                                                                             Machine Reset




                                                                                                                                                                                                                                                                                                                                         Adjustment /




                                                                                                                                                                                                                                                                                                                                                                                  Die Change
                                                                                                                                                                                                                                                                                                                                         Component


                                                                                                                                                                                                                                                                                                                                                        Positioning
                                                                                                                                                                                                                                                         at entry




                                                                                                                                                                                                                                                                                                                       Control
                                                                                                                                                   loading




                                                                                                                                                                                                                                 Points
                                           Operator:
                                                                           start
                                           John Gordon                   current
                                                                          target                    5                            5                          5                             5                      5                      5                          5                           5                             5                5                5                     5                      5
                                                                           start
                                           Jeff Goldberg                 current
                                                                          target                    4                            4                          4                             3                      4                      4                          3                           4                             4                3                4                     3                      3
                                                                           start
                                           Steve Fults                   current
                                                                          target                    4                            4                          4                             3                      4                      4                          3                           4                             4                3                4                     3                      3
                                                                           start
                                           Anthony
                                                                         current
                                           Watkins
                                                                          target                    4                            4                          4                             3                      4                      4                          3                           4                             4                3                4                     3                      3
                                                                           start
                                           Tim Anderson                  current
                                                                          target                    4                            4                          4                             3                      4                      4                          3                           4                             4                3                4                     3                      3

                                                                 Start Average:                0                             0                           0                            0                       0                       0                        0                           0                               0                0                0                     0                   0
                                                               Current Average:                0                             0                           0                            0                       0                       0                        0                           0                               0                0                0                     0                   0
                                                                        Target:               4.2                           4.2                         4.2                          3.4                     4.2                     4.2                      3.4                         4.2                             4.2              3.4              4.2                   3.4                 3.4
                                              Start GAP of Skill Level D                      4.2                           4.2                         4.2                          3.4                     4.2                     4.2                      3.4                         4.2                             4.2              3.4              4.2                   3.4                 3.4
                                              Start GAP of Skill Level C                                                    4.2                                                                              3.9                                                                    3.8                                                                     3.7
                                           Current GAP of Skill Level D                       4.2                           4.2                         4.2                          3.4                     4.2                     4.2                      3.4                         4.2                             4.2              3.4              4.2                   3.4                 3.4
                                           Current GAP of Skill Level C                                                     4.2                                                                              3.9                                                                    3.8                                                                     3.7

                                                                 Level of Knowledge
                                                               Be able to teach                                                5
                                                     Be able to do it in non std conditions                                    4
                                                      Be able to do it in std conditions                                       3
                                                               Know the theory                                                 2
                                                           Do not know the theory                                              1


                                                                           Actual          Target
                                           Cycle                                                                                                                                                                                                                                          SET-UP ADJUSTMENT LOSS
                                           Parameter
                                           Control                                  4%                        4%                                                                                                                                                                                                                                                                               Cylinder Replacement
                                           Adjustment /                                                                                                                                             35%                                                                                                                                                                                        Die Change
                                           Component                                4%                        4%
                                                                                                                                                                                                                                                                                                                                                                                               Adjustment Material Positioning
                                           Adjustment
                                                                                                                                                                                                    30%                                                                                                                                                                                        Adjustment / Component
                                           Material
                                                                                                                                                                                                                                                                                                                                                                                               Cycle Parameter Control
                                           Positioning                               7%                       7%
                                           Die Change                               10%                       5%                                                                                    25%
                                           Cylinder Replacement                      4%                       4%

                                                                                                                                                                                                    20%




                                                                                                                                                                            Loss %
                                                                                                                                                                                                    15%


                                                                                                                                                                                                    10%


                                                                                                                                                                                                        5%


                                                                                                                                                                                                        0%
                                                                                                                                                                                                                                                                                Actual                                                                                                                                       Target




                                                                                                                          START                                        1                                2                    3                    4                            5                               6                    7 TARGET
                                                                                          Before                            10%
                                                                                          Follow-up                                                            9%                               8%              11%                         6%                         4%                              5%                      3%
                                                                                          Target                                                                                                                                                                                                                                                5%


                                                                                                                                                    Die Change loss reduction follow up

                                                                            12%



                                                                            10%



                                                                             8%



                                                                             6%



                                                                             4%



                                                                             2%



                                                                             0%
                                                                                      START                                                    1                                     2                                       3                                  4                                                  5                         6                                7                    TARGET




                                                                          Before           TargetAfter Training
                                           Cycle
                                           Parameter
                                           Control                          4%                4%                            4%
                                           Adjustment /
                                           Component                        4%                4%                            4%
                                           Adjustment
                                           Material
                                           Positioning                      7%                7%                            7%
                                           Die Change                       10%               5%                            2%
                                           Cylinder Replacement             4%                4%                            4%




                                                                                                                            SET-UP ADJUSTMENT LOSS

                                                                                                                                                                                                                                                                                                     Cylinder Replacement
                                                     35%                                                                                                                                                                                                                                             Die Change
                                                                                                                                                                                                                                                                                                     Adjustment Material Positioning
                                                     30%                                                                                                                                                                                                                                             Adjustment / Component
                                                                                                                                                                                                                                                                                                     Cycle Parameter Control

                                                     25%

                                                     20%
                                            Loss %




                                                     15%

                                                     10%

                                                       5%

                                                       0%
                                                                                  Before                                                                                                                     Target                                                                                                               After Training




a1aea25d-721c-4226-a7fe-e849ab945962.xls                                                                                                                                                                                                                 Efeso © 2003
                                                                                                                                                                                                                                                                                                                                                                                                                                      2 of 15
Skill target identification                                                                                                                                                                                                                            Printed 5/27/2012
Efeso - Client name




                                           Mach:                       1                                                                     Line:                             xy

                                                                                                                   MATERIAL                                                      MAIN OPERATIONS                                                                  QUALITY                                                              SET-UP/ADJUSTMENT
                                                            AREA (level B)
                                                                                                                    (level C)                                                         (level C)                                                                   (level C)                                                                  (levelC)

                                                   Skill (level D):




                                                                                                                                                                                                                                                       Material Quality Control
                                                                                        Materials Identification




                                                                                                                                             Material Loading / Un-




                                                                                                                                                                                                                                                                                                                                                                                                    Cylinder Replacement
                                                                                                                                                                                                                               Machine Lubrication




                                                                                                                                                                                                                                                                                                                                                      Adjustment Material
                                                                                                                      Stock Management




                                                                                                                                                                                                                                                                                        PF Quality Control
                                                                                                                                                                               Machine Start-Up




                                                                                                                                                                                                                                                                                                                     Cycle Parameter
                                                                                                                                                                                                           Machine Reset




                                                                                                                                                                                                                                                                                                                                       Adjustment /




                                                                                                                                                                                                                                                                                                                                                                                Die Change
                                                                                                                                                                                                                                                                                                                                       Component


                                                                                                                                                                                                                                                                                                                                                      Positioning
                                                                                                                                                                                                                                                       at entry




                                                                                                                                                                                                                                                                                                                     Control
                                                                                                                                             loading




                                                                                                                                                                                                                               Points
                                           Operator:
                                                                     start                     5                           4                          4                             4                          4                      4                          5                           4                             4                4                2                     3                      4
                                           John Gordon             current
                                                                    target                     5                           5                          5                             5                          5                      5                          5                           5                             5                5                5                     5                      5
                                                                     start                     3                           4                          3                             2                          3                      4                          3                           4                             3                3                4                     2                      3
                                           Jeff Goldberg           current
                                                                    target                     4                           4                          4                             3                          4                      4                          3                           4                             4                3                4                     3                      3
                                                                     start                     4                           3                          3                             2                          3                      3                          2                           3                             4                2                3                     2                      3
                                           Steve Fults             current
                                                                    target                     4                           4                          4                             3                          4                      4                          3                           4                             4                3                4                     3                      3
                                                                     start                     4                           2                          4                             3                          2                      4                          2                           2                             3                2                2                     1                      2
                                           Anthony
                                                                   current
                                           Watkins
                                                                    target                     4                           4                          4                             3                          4                      4                          3                           4                             4                3                4                     3                      3
                                                                     start                     1                           3                          3                             3                          3                      3                          2                           3                             3                2                3                     1                      1
                                           Tim Anderson            current
                                                                    target                     4                           4                          4                             3                          4                      4                          3                           4                             4                3                4                     3                      3

                                                           Start Average:               3.4                           3.2                         3.4                          2.8                          3                      3.6                      2.8                         3.2                             3.4              2.6              2.8                   1.8                2.6
                                                         Current Average:                0                             0                           0                            0                           0                       0                        0                           0                               0                0                0                     0                  0
                                                                  Target:               4.2                           4.2                         4.2                          3.4                         4.2                     4.2                      3.4                         4.2                             4.2              3.4              4.2                   3.4                3.4
                                             Start GAP of Skill Level D                 0.8                            1                          0.8                          0.6                         1.2                     0.6                      0.6                              1                          0.8              0.8              1.4                   1.6                0.8
                                             Start GAP of Skill Level C                                               0.9                                                                                  0.8                                                                    0.8                                                                     1.1
                                           Current GAP of Skill Level D                 4.2                           4.2                         4.2                          3.4                         4.2                     4.2                      3.4                         4.2                             4.2              3.4              4.2                   3.4                3.4
                                           Current GAP of Skill Level C                                               4.2                                                                                  3.9                                                                    3.8                                                                     3.7

                                                           Level of Knowledge
                                                         Be able to teach                                                5
                                               Be able to do it in non std conditions                                    4
                                                 Be able to do it in std conditions                                      3
                                                         Know the theory                                                 2
                                                     Do not know the theory                                              1


                                                                     Actual          Target
                                           Cycle
                                           Parameter                                                                                                                                                                                                                                    SET-UP ADJUSTMENT LOSS
                                           Control                            4%                         4%
                                           Adjustment /                                                                                                                                                                                                                                                                                                                                      Cylinder Replacement
                                           Component                          4%                         4%                                                                                       35%                                                                                                                                                                                        Die Change
                                           Adjustment                                                                                                                                                                                                                                                                                                                                        Adjustment Material Positioning
                                           Material                                                                                                                                                                                                                                                                                                                                          Adjustment / Component
                                                                                                                                                                                                  30%
                                           Positioning                         7%                        7%
                                                                                                                                                                                                                                                                                                                                                                                             Cycle Parameter Control
                                           Die Change                         10%                        5%
                                           Cylinder Replacement                4%                        4%                                                                                       25%


                                                                                                                                                                                                  20%




                                                                                                                                                                      Loss %
                                                                                                                                                                                                  15%


                                                                                                                                                                                                  10%


                                                                                                                                                                                                      5%


                                                                                                                                                                                                      0%
                                                                                                                                                                                                                                                                                  Actual                                                                                                                                   Target




                                                                                                                     START                                       1                                2                        3                    4                            5                               6                    7 TARGET
                                                                                    Before                             10%
                                                                                    Follow-up                                                            9%                               8%                  11%                         6%                         4%                              5%                      3%
                                                                                    Target                                                                                                                                                                                                                                                    5%




                                                                                                                                             Die Change loss reduction follow up

                                                                      12%



                                                                      10%



                                                                       8%



                                                                       6%



                                                                       4%



                                                                       2%



                                                                       0%
                                                                                START                                                    1                                     2                                           3                                 4                                                   5                         6                                7                   TARGET




                                                                    Before           TargetAfter Training
                                           Cycle
                                           Parameter
                                           Control                    4%                4%                            4%
                                           Adjustment /
                                           Component                  4%                4%                            4%
                                           Adjustment
                                           Material
                                           Positioning                7%                7%                            7%
                                           Die Change                 10%               5%                            2%
                                           Cylinder Replacement       4%                4%                            4%




                                                                                                                      SET-UP ADJUSTMENT LOSS

                                                                                                                                                                                                                                                                                                             Cylinder Replacement
                                               35%
                                                                                                                                                                                                                                                                                                             Die Change
                                                                                                                                                                                                                                                                                                             Adjustment Material Positioning
                                               30%                                                                                                                                                                                                                                                           Adjustment / Component
                                                                                                                                                                                                                                                                                                             Cycle Parameter Control

                                               25%


                                               20%


                                               15%


                                               10%


                                                5%


                                                0%
                                                                           Before                                                                                                                          Target                                                                                                                After Training




a1aea25d-721c-4226-a7fe-e849ab945962.xls                                                                                                                                                                                                               Efeso © 2003
                                                                                                                                                                                                                                                                                                                                                                                                                                    3 of 15
Skill gap before training                                                                                                                                                                                                                            Printed 5/27/2012
Efeso - Client name




                                                    Start Gap of Skill Level C

                  1.8                                                            100%

                  1.6                                                            90%

                  1.4                                                            80%




                                                                                       Accumulated
                                                                                 70%
                  1.2
                                                                                 60%




                                                                                           %
                    1
    Gap




                                                                                 50%
                  0.8
                                                                                 40%
                  0.6
                                                                                 30%
                   0.4                                                           20%
          Die Change                          1.6   13.33%     13.33%
          Adjustment Material Positioning
                   0.2                        1.4   11.67%     25.00%            10%
          Machine Reset                       1.2   10.00%     35.00%
                     0                                                           0%
          PF Quality Control                    1    8.33%     43.33%
          Stock Management                      1    8.33%     51.67%
          Materials Identification            0.8    6.67%     58.33%
          Cycle Parameter Control             0.8    6.67%     65.00%
          Material Loading / Un-loading       0.8    6.67%     71.67%
          Cylinder Replacement                0.8    6.67%     78.33%
          Adjustment / Component              0.8    6.67%     85.00%
          Machine Start-Up                    0.6    5.00%     90.00%
          Machine Lubrication Points          0.6    5.00%     95.00%
                                                                    Skills
          Material Quality Control at entry   0.6    5.00%    100.00%
                                               12




a1aea25d-721c-4226-a7fe-e849ab945962.xls                       Efeso © 2003
Pareto Skill GAP                                             Printed 5/27/2012            4 of 15
Efeso - Client name




                         Check list for training module                                    Mach:        1
                          Machine Operator - Set Up                                         Line:       xy
                                                                          Operator:
                            DIE CHANGE
                                                                          Skill level to be achieved:
                                           Questions to achieve Level 3
   Nr    check points (= all Work steps for this ability)
    1     Able to prepare the die change
    2     Able to set the new product specifics
    3     Able to stop the machine in the proper sequence
    4     Able to reduce the extruder speed to the minimum
    5     Able to remove the supporting rolls
    6     Able to open raw material head
    7     Able to cut and remove from the line the previous product
    8     Able to take raw material and die out of the extruder head
    9     Able to properly clean the extruder head from the previous raw material
   10     Able to set the new die in extruder head
   11     Able to close raw material head timely
   12     Able to adjust new color code
   13     Able to calibrate scales
   14     Able to start up the extruder and splice old and new products
   15     Able to close pressure roll
   16     Able to start up production with less that ten scraps


                                           Questions to achieve Level 4
   Nr    check points (= all Work steps for this ability)
   1      Able to recognize the anomalies and classify them
   2      Able to unfasten a locked bolt
   3      Able to fix a difficult to insert die
   4      Able to center a difficult to adjust die


                                           Questions to achieve Level 5
   Nr    check points (= all Work steps for this ability)
   1      Able to clearly explain each die change key item
   2      Able to use OPLs
   3      Able to assess other people training levels
   4      Able to fill the gaps explaining concepts in a practical way

 Assessed by:                                                       Assessment Date:

                  Level of Knowledge
            Be able to teach                     5
  Be able to do it in non std conditions         4
    Be able to do it in std conditions           3
            Know the theory                      2
        Do not know the theory                   1




a1aea25d-721c-4226-a7fe-e849ab945962.xls          Efeso © 2003
DieChange activities_empty                      Printed 5/27/2012                                       5 of 15
Efeso - Client name




                         Check list for training module                                    Mach:        1
                          Machine Operator - Set Up                                         Line:       xy
                                                                          Operator
                            DIE CHANGE
                                                                          Skill level to be achieved:
                                           Questions to achieve Level 3
   Nr                   check points (= all Work steps for this ability)                   OK       not OK
    1     Able to prepare the die change
    2     Able to set the new product specifics
    3     Able to stop the machine in the proper sequence
    4     Able to reduce the extruder speed to the minimum
    5     Able to remove the supporting rolls
    6     Able to open raw material head
    7     Able to cut and remove from the line the previous product
    8     Able to take raw material and die out of the extruder head
    9     Able to properly clean the extruder head from the previous raw material
   10     Able to set the new die in extruder head
   11     Able to close raw material head timely
   12     Able to adjust new color code
   13     Able to calibrate scales
   14     Able to start up the extruder and splice old and new products
   15     Able to close pressure roll
   16     Able to start up production with less that ten scraps

                                                                          Total average:   0%
                                           Questions to achieve Level 4
   Nr                   check points (= all Work steps for this ability)                   OK       not OK
   1      Able to recognize the anomalies and classify them
   2      Able to unfasten a locked bolt
   3      Able to fix a difficult to insert die
   4      Able to center a difficult to adjust die

                                                                          Total average:   0%
                                           Questions to achieve Level 5
   Nr                     check points (= all Work steps for this ability)                 OK       not OK
   1      Able to clearly explain each die change key item
   2      Able to use OPLs
   3      Able to assess other people training levels
   4      Able to fill the gaps explaining concepts in a practical way

                                                                          Total average:   0%
 Assessed by:                                                       Assessment Date:

                  Level of Knowledge
            Be able to teach                     5
  Be able to do it in non std conditions         4
    Be able to do it in std conditions           3
            Know the theory                      2
        Do not know the theory                   1




a1aea25d-721c-4226-a7fe-e849ab945962.xls          Efeso © 2003
DieChange check list_empty                      Printed 5/27/2012                                       6 of 15
Efeso - Client name




                         Check list for training module                                     Mach:     1
                          Machine Operator - Set Up                                           Line:   xy
                                                                          Operator          John Gordon
                            DIE CHANGE
                                                                          Skill level to be achieved: 5
                                           Questions to achieve Level 3
   Nr                   check points (= all Work steps for this ability)                   OK     not OK
    1     Able to prepare the die change                                                    x
    2     Able to set the new product specifics                                             x
    3     Able to stop the machine in the proper sequence                                   x
    4     Able to reduce the extruder speed to the minimum                                  x
    5     Able to remove the supporting rolls                                               x
    6     Able to open raw material head                                                    x
    7     Able to cut and remove from the line the previous product                         x
    8     Able to take raw material and die out of the extruder head                        x
    9     Able to properly clean the extruder head from the previous raw material           x
   10     Able to set the new die in extruder head                                          x
   11     Able to close raw material head timely                                            x
   12     Able to adjust new color code                                                     x
   13     Able to calibrate scales                                                          x
   14     Able to start up the extruder and splice old and new products                     x
   15     Able to close pressure roll                                                       x
   16     Able to start up production with less that ten scraps                             x

                                                                          Total average:   100%
                                           Questions to achieve Level 4
   Nr                   check points (= all Work steps for this ability)                   OK     not OK
   1      Able to recognize the anomalies and classify them                                 x
   2      Able to unfasten a locked bolt                                                    x
   3      Able to fix a difficult to insert die                                             x
   4      Able to center a difficult to adjust die                                          x

                                                                          Total average:   100%
                                           Questions to achieve Level 5
   Nr                     check points (= all Work steps for this ability)                 OK     not OK
   1      Able to clearly explain each die change key item                                           x
   2      Able to use OPLs                                                                  x
   3      Able to assess other people training levels                                       x
   4      Able to fill the gaps explaining concepts in a practical way                               x

                                                                          Total average:   50%
 Assessed by:                                                       Assessment Date:

                  Level of Knowledge
            Be able to teach                     5
  Be able to do it in non std conditions         4
    Be able to do it in std conditions           3
            Know the theory                      2
        Do not know the theory                   1




a1aea25d-721c-4226-a7fe-e849ab945962.xls          Efeso © 2003
DieChange check list_Gordon                     Printed 5/27/2012                                    7 of 15
Efeso - Client name




                         Check list for training module                                      Mach:    1
                          Machine Operator - Set Up                                           Line:   xy
                                                                          Operator          Jeff Goldberg
                            DIE CHANGE
                                                                          Skill level to be achieved: 3
                                           Questions to achieve Level 3
   Nr                   check points (= all Work steps for this ability)                   OK      not OK
    1     Able to prepare the die change                                                    x
    2     Able to set the new product specifics                                             x
    3     Able to stop the machine in the proper sequence                                             x
    4     Able to reduce the extruder speed to the minimum                                  x
    5     Able to remove the supporting rolls                                               x
    6     Able to open raw material head                                                    x
    7     Able to cut and remove from the line the previous product                                   x
    8     Able to take raw material and die out of the extruder head                        x
    9     Able to properly clean the extruder head from the previous raw material                     x
   10     Able to set the new die in extruder head                                          x
   11     Able to close raw material head timely                                                      x
   12     Able to adjust new color code                                                     x
   13     Able to calibrate scales                                                          x
   14     Able to start up the extruder and splice old and new products                     x
   15     Able to close pressure roll                                                       x
   16     Able to start up production with less that ten scraps                                       x

                                                                          Total average:   69%
                                           Questions to achieve Level 4
   Nr                   check points (= all Work steps for this ability)                   OK      not OK
   1      Able to recognize the anomalies and classify them
   2      Able to unfasten a locked bolt
   3      Able to fix a difficult to insert die
   4      Able to center a difficult to adjust die

                                                                          Total average:   0%
                                           Questions to achieve Level 5
   Nr                     check points (= all Work steps for this ability)                 OK      not OK
   1      Able to clearly explain each die change key item
   2      Able to use OPLs
   3      Able to assess other people training levels
   4      Able to fill the gaps explaining concepts in a practical way

                                                                          Total average:   0%
 Assessed by:                                                       Assessment Date:

                  Level of Knowledge
            Be able to teach                     5
  Be able to do it in non std conditions         4
    Be able to do it in std conditions           3
            Know the theory                      2
        Do not know the theory                   1




a1aea25d-721c-4226-a7fe-e849ab945962.xls          Efeso © 2003
DieChange check list_Goldberg                   Printed 5/27/2012                                     8 of 15
Efeso - Client name




                         Check list for training module                                     Mach:      1
                          Machine Operator - Set Up                                           Line:   xy
                                                                          Operator           Steve Fults
                            DIE CHANGE
                                                                          Skill level to be achieved:    3
                                           Questions to achieve Level 3
   Nr                   check points (= all Work steps for this ability)                   OK       not OK
    1     Able to prepare the die change                                                    x
    2     Able to set the new product specifics                                             x
    3     Able to stop the machine in the proper sequence                                   x
    4     Able to reduce the extruder speed to the minimum                                  x
    5     Able to remove the supporting rolls                                               x
    6     Able to open raw material head                                                    x
    7     Able to cut and remove from the line the previous product                         x
    8     Able to take raw material and die out of the extruder head                        x
    9     Able to properly clean the extruder head from the previous raw material           x
   10     Able to set the new die in extruder head                                          x
   11     Able to close raw material head timely                                            x
   12     Able to adjust new color code                                                     x
   13     Able to calibrate scales                                                          x
   14     Able to start up the extruder and splice old and new products                     x
   15     Able to close pressure roll                                                       x
   16     Able to start up production with less that ten scraps                             x

                                                                          Total average:   100%
                                           Questions to achieve Level 4
   Nr                   check points (= all Work steps for this ability)                   OK       not OK
   1      Able to recognize the anomalies and classify them
   2      Able to unfasten a locked bolt
   3      Able to fix a difficult to insert die
   4      Able to center a difficult to adjust die

                                                                          Total average:   0%
                                           Questions to achieve Level 5
   Nr                     check points (= all Work steps for this ability)                 OK       not OK
   1      Able to clearly explain each die change key item
   2      Able to use OPLs
   3      Able to assess other people training levels
   4      Able to fill the gaps explaining concepts in a practical way

                                                                          Total average:   0%
 Assessed by:                                                       Assessment Date:

                  Level of Knowledge
            Be able to teach                     5
  Be able to do it in non std conditions         4
    Be able to do it in std conditions           3
            Know the theory                      2
        Do not know the theory                   1




a1aea25d-721c-4226-a7fe-e849ab945962.xls          Efeso © 2003
DieChange check list_Fults                      Printed 5/27/2012                                      9 of 15
Efeso - Client name




                         Check list for training module                                    Mach:      1
                          Machine Operator - Set Up                                         Line:     xy
                                                                          Operator         Anthony Watkins
                            DIE CHANGE
                                                                          Skill level to be achieved: 3
                                           Questions to achieve Level 3
   Nr                   check points (= all Work steps for this ability)                   OK       not OK
    1     Able to prepare the die change                                                    x
    2     Able to set the new product specifics                                             x
    3     Able to stop the machine in the proper sequence                                   x
    4     Able to reduce the extruder speed to the minimum                                  x
    5     Able to remove the supporting rolls                                               x
    6     Able to open raw material head                                                    x
    7     Able to cut and remove from the line the previous product                         x
    8     Able to take raw material and die out of the extruder head                        x
    9     Able to properly clean the extruder head from the previous raw material           x
   10     Able to set the new die in extruder head                                          x
   11     Able to close raw material head timely                                            x
   12     Able to adjust new color code                                                     x
   13     Able to calibrate scales                                                          x
   14     Able to start up the extruder and splice old and new products                     x
   15     Able to close pressure roll                                                       x
   16     Able to start up production with less that ten scraps                             x

                                                                          Total average:   100%
                                           Questions to achieve Level 4
   Nr                   check points (= all Work steps for this ability)                   OK       not OK
   1      Able to recognize the anomalies and classify them
   2      Able to unfasten a locked bolt
   3      Able to fix a difficult to insert die
   4      Able to center a difficult to adjust die

                                                                          Total average:   0%
                                           Questions to achieve Level 5
   Nr                     check points (= all Work steps for this ability)                 OK       not OK
   1      Able to clearly explain each die change key item
   2      Able to use OPLs
   3      Able to assess other people training levels
   4      Able to fill the gaps explaining concepts in a practical way

                                                                          Total average:   0%
 Assessed by:                                                       Assessment Date:

                  Level of Knowledge
            Be able to teach                     5
  Be able to do it in non std conditions         4
    Be able to do it in std conditions           3
            Know the theory                      2
        Do not know the theory                   1




a1aea25d-721c-4226-a7fe-e849ab945962.xls          Efeso © 2003
DieChange check list_ Watkins                   Printed 5/27/2012                                     10 of 15
Efeso - Client name




                         Check list for training module                                      Mach:    1
                          Machine Operator - Set Up                                           Line:   xy
                                                                          Operator          Tim Anderson
                            DIE CHANGE
                                                                          Skill level to be achieved:    3
                                           Questions to achieve Level 3
   Nr                   check points (= all Work steps for this ability)                   OK       not OK
    1     Able to prepare the die change                                                    x
    2     Able to set the new product specifics                                             x
    3     Able to stop the machine in the proper sequence                                   x
    4     Able to reduce the extruder speed to the minimum                                  x
    5     Able to remove the supporting rolls                                               x
    6     Able to open raw material head                                                    x
    7     Able to cut and remove from the line the previous product                         x
    8     Able to take raw material and die out of the extruder head                        x
    9     Able to properly clean the extruder head from the previous raw material           x
   10     Able to set the new die in extruder head                                          x
   11     Able to close raw material head timely                                            x
   12     Able to adjust new color code                                                     x
   13     Able to calibrate scales                                                          x
   14     Able to start up the extruder and splice old and new products                     x
   15     Able to close pressure roll                                                       x
   16     Able to start up production with less that ten scraps                             x

                                                                          Total average:   100%
                                           Questions to achieve Level 4
   Nr                   check points (= all Work steps for this ability)                   OK       not OK
   1      Able to recognize the anomalies and classify them
   2      Able to unfasten a locked bolt
   3      Able to fix a difficult to insert die
   4      Able to center a difficult to adjust die

                                                                          Total average:   0%
                                           Questions to achieve Level 5
   Nr                     check points (= all Work steps for this ability)                 OK       not OK
   1      Able to clearly explain each die change key item
   2      Able to use OPLs
   3      Able to assess other people training levels
   4      Able to fill the gaps explaining concepts in a practical way

                                                                          Total average:   0%
 Assessed by:                                                       Assessment Date:

                  Level of Knowledge
            Be able to teach                     5
  Be able to do it in non std conditions         4
    Be able to do it in std conditions           3
            Know the theory                      2
        Do not know the theory                   1




a1aea25d-721c-4226-a7fe-e849ab945962.xls          Efeso © 2003
DieChange check list_ Anderson                  Printed 5/27/2012                                     11 of 15
Efeso - Client name




      Mach:                       1                                                         Line:                    xy

                                                                      MATERIAL                                         MAIN OPERATIONS                                                    QUALITY                                                              SET-UP/ADJUSTMENT
                         AREA (level B)                                (level C)                                            (level C)                                                     (level C)                                                                  (level C)




                                                                                                                                                                                                                                     Cycle Parameter Control
                                                                                                                                                                               Material Quality Control
                  Skill (level D):




                                           Materials Identification




                                                                                                                                                                                                                                                                                                                 Cylinder Replacement
                                                                                            Material Loading / Un-




                                                                                                                                                         Machine Lubrication




                                                                                                                                                                                                                                                                              Adjustment Material
                                                                         Stock Management




                                                                                                                                                                                                                PF Quality Control
                                                                                                                      Machine Start-Up


                                                                                                                                         Machine Reset




                                                                                                                                                                                                                                                               Adjustment /




                                                                                                                                                                                                                                                                                                    Die Change
                                                                                                                                                                                                                                                               Component


                                                                                                                                                                                                                                                                              Positioning
                                                                                                                                                                               at entry
                                                                                            loading




                                                                                                                                                         Points
      Operator:
                                start          5                            4                       4                    4                 4                    4                       5                          4                     4                         4                 2                3              4
      John Gordon             current          5                            4                       4                    4                 4                    4                       5                          4                     4                         4                 2                5              4
                               target          5                            5                       5                    5                 5                    5                       5                          5                     5                         5                 5                5              5
                                start          3                            4                       3                    2                 3                    4                       3                          4                     3                         3                 4                2              3
      Jeff Goldberg           current          3                            4                       3                    2                 3                    4                       3                          4                     3                         3                 4                2              3
                               target          4                            4                       4                    3                 4                    4                       3                          4                     4                         3                 4                3              3
                                start          4                            3                       3                    2                 3                    3                       2                          3                     4                         2                 3                2              3
      Steve Fults             current          4                            3                       3                    2                 3                    3                       2                          3                     4                         2                 3                3              3
                               target          4                            4                       4                    3                 4                    4                       3                          4                     4                         3                 4                3              3
                                start          4                            2                       4                    3                 2                    4                       2                          2                     3                         2                 2                1              2
      Anthony Watkins         current          4                            2                       4                    3                 2                    4                       2                          2                     3                         2                 2                3              2
                               target          4                            4                       4                    3                 4                    4                       3                          4                     4                         3                 4                3              3
                                start          1                            3                       3                    3                 3                    3                       2                          3                     3                         2                 3                1              1
      Tim Anderson            current          1                            3                       3                    3                 3                    3                       2                          3                     3                         2                 3                3              1
                               target          4                            4                       4                    3                 4                    4                       3                          4                     4                         3                 4                3              3

                        Start Average:     3.4                           3.2                    3.4                  2.8                  3                 3.6                    2.8                          3.2                  3.4                         2.6             2.8                1.8          2.6
                      Current Average:     3.4                           3.2                    3.4                  2.8                  3                 3.6                    2.8                          3.2                  3.4                         2.6             2.8                3.2          2.6
                               Target:     4.2                           4.2                    4.2                  3.4                 4.2                4.2                    3.4                          4.2                  4.2                         3.4             4.2                3.4          3.4

          Start GAP of Skill Level D       0.8                            1                     0.8                  0.6                 1.2                0.6                    0.6                             1                 0.8                         0.8             1.4                1.6          0.8
          Start GAP of Skill Level C                                     0.9                                                             0.8                                                              0.8                                                                    1.1




a1aea25d-721c-4226-a7fe-e849ab945962.xls                                                                               Efeso © 2003
SkillGapAfterDieChangeTraining                                                                                       Printed 5/27/2012                                                                                                                                                                                       12 of 15
Efeso - Client name




        Current GAP of Skill Level D                  0.8    1    0.8   0.6      1.2        0.6   0.6         1   0.8   0.8   1.4   0.2   0.8
        Current GAP of Skill Level C                        0.9                  0.8                    0.8                   0.8

                         Level of Knowledge
                       Be able to teach                     5
             Be able to do it in non std conditions         4
               Be able to do it in std conditions           3
                       Know the theory                      2
                   Do not know the theory                   1




a1aea25d-721c-4226-a7fe-e849ab945962.xls                                  Efeso © 2003
SkillGapAfterDieChangeTraining                                          Printed 5/27/2012                                                  13 of 15
Efeso - Client name




                                  Skill gap analysis after Die Change Training
              Level of
             knowledge
                 5                                                                                        start
                                                                                                          current
                                                                                                          target
                 4                                                                                        start gap
                                                                                                          current gap
                 3

                 2

                 1

                 0
                        John Gordon Jeff Goldberg      Steve Fults           Anthony       Tim Anderson                 average
                                                                             Watkins


                                           start   current   target start gapcurrent gap
      John Gordon                            3        5         5       2         1
      Jeff Goldberg                          2        2         3       1         1
      Steve Fults                            2        3         3       1         0
      Anthony Watkins                        1        3         3       2         0
      Tim Anderson                           1        3         3       2         0

      average                              1.8      3.2       3.4      1.6      0.2




a1aea25d-721c-4226-a7fe-e849ab945962.xls                                Efeso © 2003
SkillGapAfterDieChangeTraining                                        Printed 5/27/2012                                           14 of 15
Efeso - Client name




                                                          Die Change Operation


                                                       John Gordon
                                                         5
                                                         4
                                                         3
                                                         2
                      Tim Anderson                                                       Jeff Goldberg
                                                         1
                                                         0

                                                                                                         target
                                                                                                         after second training
                                                                                                         after first training
                                    Anthony                                                              before training
                                                                               Steve Fults
                                    Watkins



                                        after after second training
                            before training first training      target
   John Gordon                    3             4          5       5
   Jeff Goldberg                  2             2          3       3
   Steve Fults                    2             3          3       3
   Anthony Watkins                1             3          3       3
   Tim Anderson                   1             3          3       3




a1aea25d-721c-4226-a7fe-e849ab945962.xls                                   Efeso © 2003
SkillGapAfterDieChangeTraining                                           Printed 5/27/2012                                       15 of 15

								
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