| Client: Fortune 500 Manufacturer of Timber Products for the Construction & Do-It-Yourself Markets |
Client Success Stories
Charles Brooks Associates, Inc
| BACKGROUND: Sixty million dollars allocated for construction and start-up of a sawmill with new state-of-the-art equipment. There was no experience within the company in the start-up, operation and maintenance of the selected equipment. The conceptual plan was to implement a TEAM manufacturing and management environment. The regional unemployment rate was less than 3.0%, with a need for approximately 2,000 applications to be placed into the recruitment/assessment process. There were no plans for the recruitment and training of team members, as well as no personnel policies or management strategies. State funding of training efforts was necessary. ACTIONS: CBA and project managers developed: A Gantt chart of major activities to be completed prior to commissioning and start-up activities. Personnel policies to be refined by manufacturing team members. Strategies to ensure approximately 2,000 applications for employment would be submitted. CBA and the Project Training Manager: Trained 14 team leaders in the principles and techniques of the Analytical Method of Training. Developed a timeline for the analysis of work in ten areas. Prepared and presented the request for state training funds to representatives of the community college system. Coordinated the analysis of work activities by 14 team leaders at locations across the United States and in Germany. Scheduled the start dates for all members of the work force. Assisted the 14 team leaders in scheduling and conducting training sessions and exercises for over 100 manufacturing team members. Coordinated the use of manufacturing team members in the facility commissioning and start-up activities. RESULTS: Creation of manufacturing facility employing an all-salaried work force in which team members participate fully in the decision-making process. Implementation of an intensive, skills-based training program for a new facility. Qualified applicants trained and ready to move into manufacturing roles when commissioning and start-up activities began. Development of a flexible work force in which employees are cross-trained and compensated for additional skills. Development of manufacturing team members who understand their roles in the production process and who are actively involved in problem identification and resolution. The attainment of start-up productivity levels that exceeded the estimated targets. The use of this facility by division management as the role model for new operation start-ups |
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