Training Needs in Manufacturing

There was, and still is, a need for a 24/7 online training program. Today, employee training is decreasing. There is a knowledge gap between employee and machine capability that is increasing. Put those together, and add in the fact that a large number of baby boomers will be retiring within the next three to eight years, and there was an opportunity. Jergens saw this opportunity and is still addressing and filling those needs today.

The original thought from Jergens was that if people knew more about workholding, they would be more likely to make their purchases from Jergens. After seeing the above-mentioned need for a training program that could help resolve current and future training issues, Jergens decided to go in a different direction and create a separate company – ToolingU. Their main principles were to develop a curriculum that could help bridge the gap between what employers want, and what employees can offer, closer together. Today, they do this by offering a wide range of classes that include fundamental skills, basic math, and introduction to blue print reading, for the entry-level person, to advanced classes in Six Sigma, CNC programming, and calculus, for those that are at a higher level.

With the increased number of retirees coming in the near future, along with the poor economic times over the past 18 months, ToolingU has seen a significant uptick in their enrollment. When asked about why this is, Chad Schron, ToolingU’s vice president of operations replies “Training is somewhat counter-cyclical to the economy as a whole; we have seen a real increase in our enrollment this year with the recession. Many companies are also increasing their training because there are a lot of retirements going on with people’s 401k’s having semi-recovered.”

These difficult times are not limited to the people of the U.S. either, which is why ToolingU also offers their classes in Chinese and Spanish, making them applicable throughout the world.

ToolingU has a list of industry partners – board level and management level individuals that work with them to help with the curriculum – making sure that it is up to date with the improving technologies.

Typical Benefits
“We see a lot of business coming in from all areas of manufacturing. Some of the students that sign up cannot tell the difference between a lathe and a mill, while others are here to enhance there skills as a CNC programmer or operator,” Schron states. “The classes that are offered are not just how-to classes; there are also classes on composites, describing what they are, how and why to use them, and how they are created. Either way, when a student graduates with a certificate from ToolingU, they will have the know-how to support the manufacturing environment of which they are a part.”

Not only do the students get the training that is needed, they also receive many other benefits as well. The most beneficial is the fact that the program is tailored to each individual student, since every student has a different level of knowledge and comprehension. This is another reason why the 24/7 opportunity is so important; if a student is having a particular issue with a certain section, they can continually review that section until they have a complete understanding and confidence of the material.

Additionally, many company quality programs today require a form of continuous improvement and, with Tooling U, employers can get an updated status on the student’s progress. “Everything that the student does online is documented and recorded. That way if the company has a quality mandate to comply with their ISO, GS, or QS standards, it is readily available,” Schron explains.

Training through ToolingU has shown increases in production on the work floor, as well as improved employee exchange on projects and tasks.
Other Users
In addition to companies utilizing ToolingU to train employees, ToolingU is also offered in many high schools, vocational institutions, and community colleges. The perfect example of this can be found in Dayton, OH, where a learning program – SkillsTrac – is currently using ToolingU’s classes and programs to help educate some of the members of their displaced and under skilled workforce.

SkillsTrac is a blended learning program that utilizes ToolingU’s online content with a series of Hands-On Validation Lab exercises. These exercises can be completed at one of the four lab locations in the Greater Dayton area, giving students an opportunity to train on state-of-the-art machines in conjunction with what they have learned online. The typical lab usually runs from four to eight hours, with an occasional lab going for as long 16 hours.

According to SkillsTrac Programming Director, Ray Lepore, “What we are teaching transcends all industries. We have manufacturers that supply to aerospace, medical, automotive, and even some in the food processing industries.” 

Needs and Wants
With many members of the baby boomers generation getting ready to enter the retirement part of their lives in the next three to eight years, many manufacturers are preparing to replace them with younger individuals that have the interest and desire to do this type of work. “These individuals need training before entering the workforce, by and large they are not getting the training they need in high school, and most colleges do not do a very good job of ultimately teaching these young individuals what industrial machining is all about,” Lepore says.

The other problem that many manu­facturers see, according to Lepore, is that many of the senior employees are not up to speed on computers. “There are all types of sophisticated equipment out there, and the traditional maintenance people do not have a clue what to do with them,” Lepore states. “The problem with this is that the machinery is not running at the efficiency levels for which they were intended. By running at a lower efficiency level, the cost per part increases, profits decrease, and the potential for scrap increases.”

Since its inception on October 1, 2007, SkillsTrac has had more than 340 students participate in the program with more than 200 active participants. During that time, they have issued certificates to more than 125 students, with many of those students receiving multiple certificates.

The program was funded through a $2 million grant by the U.S. Department of Labor that is expected to expire in July, 2010. With training costs of $2,000 per year, or $5,000 for the average certificate, manufacturers will have to start paying the bill on their own. However, that may not hurt current displaced workers, as their tuition may still be covered by Workforce Investment Act Money (WIA Money).

So, with the need for an ever-improving workforce being as apparent as it is in today’s manufacturing environment, ToolingU is delivering answers to companies, schools, and the workforce in general.

ToolingU
Cleveland, OH
toolingu.com

SkillsTrac
Dayton, OH
skillstrac.com