Tube Fab/Roman Engineering sought to improve their business performance, employee engagement, morale and retention. To do this, they focused on specific employee trainings which would impact one or more of these needs. With the help of Michigan Works! Northeast Consortium, Tube Fab/Roman Engineering was awarded a Going PRO Training Fund grant of $25,200 to train 17 existing employees in trainings including Poka Yoke, Applied Project Management, A3 Problem Solving, Power Inspect Training and Support (welding), Lean Manufacturing Champion, and Lean Office Champion.
Tube Fab HR reported that their most significant ongoing need is the development of skills in frontline supervision, which has been reflected back through employee engagement surveys, as well as exit interviews. In order to improve onboarding, training, job relations, and operational improvement, upskilling of their Team Leader job function was imperative. Revision and enhancement of a multi-level Team Leader job structure would result in more effective floor-level leadership and many of the key skills needed were included in Michigan Manufacturing Technology Center’s Front-line Leader training programs.
Another key element of the company strategy is to more effectively develop new products that can consistently meet the quality expectations of customers. Seven employees received Poka Yoke (Mistake Proofing) training from the Michigan Manufacturing Technology Center. Poka Yoke training improves the knowledge and understanding of quality management techniques potentially preparing trainees for career advancement opportunities. Additionally, Poka Yoke methods can reduce the occurrence of errors, which in turn reduces the associated costs of rework and waste. Further impacts could include improved quality leading to improved customer satisfaction. With improvement of quality and reduction of errors, there could be an enhancement of overall reputation for the business within the market. Trainees also experienced a boost in confidence and felt more involved in the quality improvement initiatives, in turn building upon employee engagement for the business.
With the Applied Project Management Training from the Michigan Manufacturing Technology Center, Tube Fab will benefit with consistency in project delivery, higher return on investment from projects and will foster a culture of excellence.
The A3 Problem Solving training from the Michigan Manufacturing Technology Center will provide trainees a more structured approach to problem solving. After this training, employees will see the whole picture and be able to analyze the root cause of the problem to solve before taking action on a perceived solution.
Devin, a Welding & Controls Engineer received Certified Welding Inspector training from the American Welding Society. Now positioned as a key member of the team, Devin is the only member with the credentials to instruct and certify welders within the company. As a young engineer, this training shows investment in Devin's future with the company. Devin's certification allows the company to otherwise invest funds and resources that would be necessary to build welding skills for its employees.
Lastly, Tube Fab/Roman Engineering continues a program of Lean Champion rotational assignments for developing key talent in the use of lean practices to improve business performance. This rotational program has been in place for four years, using the Lean Manufacturing Champion training program through MMTC, and success is evidenced by the promotions of two graduates being promoted into key leadership positions in purchasing and quality. Developing this talent to promote from within is a key strategic objective for the company. The two team leads who completed Lean Practitioner training received essential tools for building efficiency into the work systems in the plant, learning how to work through structured problem-solving, apply 5S organizational skills, understand the concepts of pull production, cellular flow, and single piece flow. It also exposed the employees to standard work to aid in quality improvement and speed training. Employing members who understand the lean concepts taught in the course greatly increases efficiency and profitability for the organization.
Tube Fab has made significant investment in developing talent in this region of scarcity and this has included significant capital investment. Beyond ongoing investment in robots/cobots and other advanced automation, three years ago they commissioned a beautiful training facility that the company ownership invested in to provide a place to develop not only Tube Fab team members, but as a resource for the community. Tube Fab is continuing to enhance this in the coming year by the installation of a model production line where learners have a place to practice “learn by doing”. The intent of much of the mentioned training is to utilize this facility with MMTC to provide regional options for other employers as well.
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