Project Updates

Ohio

Proactive Technologies has been working with one visionary company for over 15 years! Triumph Thermal Systems, LLC of Forest OH. Triumph Thermal Systems is an aerospace engine components manufacturer and Federal Aviation Administration repair station. In 2000, Triumph Thermal Systems was faced with 40% of their experienced production workers retiring in the coming year 2 years; 80% in the next 4-5 years.

Proactive Technologies, Inc. was brought in to perform job/task analysis on each job classification (capturing the critical best practice processes for each job task as performed by the retiring expert), develop structured on-the-job training materials for the “accelerated transfer of expertise^TM” from the expert to the new-hire, and manage the process to ensure the transfer was effective and documented. Job classifications were targeted based on retirement dates and the company was able to capture all the critical information before it left for good.

The project is an ongoing success. With occasional funding from the state of Ohio, each of Triumph’s 19 production job classifications were similarly analyzed and worker development programs were created. Each program leads to either a “Certificate of Job Mastery^TM” portfolio or  “Certificate of Task Mastery^TM” conveyed in partnership with The Ohio State University-Marion Alber Enterprise Center. To date, 81 Certificates of Job Mastery have been conveyed along with 176 Certificates of Task Mastery (structured on-the-job training requirements still remain) were issued. Many have made progress in multiple job areas, with some receiving more that one Certificate of Job Mastery portfolios.

In addition to better management of worker capacity, the infrastructure established to support the project have supported LEAN improvements, compliance with internal quality programs and proved to be a significant asset to ISO and AS compliance, drawing praise from auditors and customers on many occasions. Triumph is currently considering registering some, if not all, of their production job classifications with the Ohio Apprenticeship Council under the new competency and/or “hybrid models” approved by the Ohio legislature in 2014.

For More Information see Proactive Technologies’ Report – Spring/Summer 2004 and Proactive Technologies’ Report – Summer 2008.

GrafTech International Holdings, LLC has several facilities and Proactive Technologies, Inc. has helped the company to establish “hybrid” workforce development programs – a blend of structured on-the-job training (“SOJT”) and relevant related technical instruction – at three of their facilities. Supported by OH Incumbent Worker Training Grants, the Lakewood facility started their project in 2012 and have 7 manufacturing job classifications SOJT programs set-up and in sync with the corresponding work processes. To date, 21 Certificates of Job Mastery and 139 Certificates of Task Mastery have been conveyed.

This program was replicated at the Sharon Center facility started in 2013 and currently has 4 jobs with blended worker training programs. Although no one yet has reached full job mastery at the Sharon Center, that should change this year as many complete the training for their current assignment. So far, Certificates of Task Mastery have been conveyed to 39 employees.

The new GrafTech Offsite Fabrication Center in Parma joined the program and is in the early stages of implementing SOJT in two job areas.

GrafTech International is a global company with 125 years of graphite material science expertise. The company manufactures graphite electrodes, which are essential to the production of electric arc furnace steel, and needle coke, the key raw material in the production of graphite electrodes.

GrafTech also manufactures graphite products and provide service for customers in more than 65 countries that represent a wide range of industries and end markets, including steel manufacturing, latest-generation electronics, oil and gas exploration, transportation, and advanced energy.

Training continues for incumbent workers to close any skill gaps, and all new-hires immediately start on their development track to reach the same goal of full job mastery. Related technical instruction is scheduled concurrently with the SOJT and is delivered by a mix of community college, university, online training providers such as New Horizons-Great Lakes, and private providers such as Lifetime Learning.

Both Lakewood and Sharon Center facilities are considering registering their Maintenance programs with the Ohio Apprenticeship Council as apprenticeships.

For more information on the hybrid approach to worker development click here.

South Carolina

Waldrop, Inc. in Spartanburg, SC – a statewide facilities maintenance company – has continued its apprenticeship program which started in 2005. With the exception of the Great Recession years, the Company has experienced substantial growth which strained its existing staff and constrained Waldrop’s ability to take on new projects.

Proactive Technologies, Inc. set up the structured on-the-job training and Spartanburg Community College delivered the related technical instruction in a “hybrid apprenticeship” model registered with ApprenticeshipSC. Waldrop determined this workforce development strategy could significantly help them with an important part of their growth plan. Recognizing the economic benefits, Waldrop sought to raise “worker capacity” by making sure every employee receives complete and consistent training and is certified to the high quality benchmark.

Waldrop started by focusing its efforts on the job classification “HVAC Service Technician,” then replicated that success to include the Plumber, Sheetmetal Technician and Pipefitter positions. Over 170 employees have participated in the program so far, with 60 receiving “Certificate of Job Mastery” portfolios. Once the related technical instruction was completed, copies of the Certificate of Job Mastery portfolio and transcripts were sent to ApprenticeshipSC, which makes the employee eligible for a Certificate of Apprenticeship Completion.

For more information about the apprenticeship model click here.

Another employer that partnered with Proactive Technologies and Spartanburg Community College is South Carolina Core Molding Technologies of Gaffney, a manufacturer of Thermoset and Thermoplastic Compression Molding products. The company relies heavily, as most companies do, on their team of Maintenance Mechanics to keep the operation running efficiently. Additionally, like most employers experience, finding experience maintenance candidates was difficult at best.

In 2006, Proactive Technologies, Inc, was asked to set up the structured on-the-job training program for the Maintenance position while the Mechatronics related technical instruction program was developed and delivered for Core Molding by Spartanburg Community College, and both registered with ApprenticeSC. The program has continued, with one more employee receiving their Certificate of Apprenticeship Completion in early 2015.

Since 2005, Proactive Technologies has partnered with five South Carolina community and technical colleges to establish hybrid apprenticeship programs in their region. The employer partners included are: PlyGem Siding Products (formally Alcoa Home Building Products),  Barnet Polymers, Core Molding Technologies, Cooper Standard Automotive, Goodyear Tire and Rubber, Invista, Lear Corporation, Gestamp (formally LSP Automotive), National Starch,  Omnova, Schwan’s Bakery, SEW Eurodrive. Timken Company, Tyco Electronics and Waldrop Inc.

Funded in part with grant money provided by the Upstate Alliance for Technical Training and by, in some cases, AdvanceSC, each company was allowed to experience the approach for themselves. As a result, many of the programs were registered with ApprenticeshipSC and several employers expanded their projects to include additional job classifications at their facility.

Read more about South Carolina Projects click here.