"I need to know how long it should take to
train a new machine operator and how I go about doing this on my own for other jobs?" B.T. North Carolina "I need to know how long it should take to
train a new machine operator and how I go about doing this on my own for other jobs?" B.T. North Carolina
THE INDUSTRY ADVISOR
DEVELOPING AND USING TRAINING CURVES
By Gene Levine - www.genelevine.com
Assuming you have a formal training program planned, the following
is one-way you might develop training curves for machine operators within your factory.
First, the many factors (explained below) that effect training times would be analyzed, for example; are you using the most suitable machines, work-aids and methods? I would then do a job analysis to determine your company’s approach to manufacturing and then validate your present production standard on the job you're questioning. Finally, little things like; the chairs, lighting, material weight and condition of machinery are scrutinized because they also help determine required training times. The entire list of considerations can be found in our Basic Time Study Manual.
Once the need for basic information was satisfied I would have you refer to our comprehensive training time data base which assigns point values to all the observed information. I will now give you a glimpse of seven of the basic tables that make up this data base so you can visualize how training curves could be developed.
DATA FOR DETERMINING REQUIRED JOB CONTENT LEVELS AND LEARNERS EXPECTED WEEKLY EFFICIENCY
| A. | COORDINATION |
DEGREE |
POINT VALUE |
|
| 1. Very Slight | No simultaneous motions, use of one part of the body | 0-3 |
| 2. Slight | Simultaneous motions by two parts of the body | 4-9 |
| 3. Average | Simultaneous motions by three parts of the body | 10-15 |
| 4. Considerable | Simultaneous motions by four parts of the body | 16-21 |
| 5. Extreme | Simultaneous motions using more than four parts of the body | 22-27 |
| B. | PRECISION |
DEGREE |
POINT VALUE |
|
| 1. Little Tolerance | More than 3/32" tolerance on operation | 0-2 |
| 2. Loose | 1/16" to 3/32 tolerance on operation | 3-6 |
| 3. Close | 1/16" to 1/32" tolerance on operation | 7-12 |
| 4. Tight | 1/32" to 1/64" tolerance on operation | 13-18 |
| 5. Exact | No tolerance allowed on operation | 19-24 |
| C. | NUMBER OF PARTS HANDLED |
POINT VALUE |
|
| 1. Only one Part to Position | 1 |
| 2. Two Parts to Position | 2 |
| 3. Three Parts to Position | 3 |
| 4. Four Parts to Position | 4 |
| 5. Five Parts to Position | 5 |
| D. | EFFORT |
DEGREE |
POINT VALUE |
|
| 1. Minimal | Automatic equipment . Operator watches several machines and occasionally moves material to re-align it. Very little physical work. Material weight 0-1 pound. | 0-1 |
| 2. Slight | Material very easy to handle. Equipment semi-automatic, where operator only feeds machine. Machine paced jobs. Often a change of pace and short rest periods while machine is doing work. Material weight 0-1 pound. | 1-2 |
| 3. Average | Material easy to handle. Easy to difficult equipment to use. Consistent work pace and occasional short rest periods. Material weight 1-3 pounds. | 3-4 |
| 4. Considerable | Difficult material to handle. Complex equipment. Considerable pace. Rest periods only at breaks and lunch. Material weight 3-4 pounds. | 5-6 |
| 5. Appreciable | Extremely difficult material to handle. Advanced computerized equipment. Very high pace. Rotating rest periods and lunch. Material weight over 4 pounds. | 7-8 |
| E. | REPETITIVENESS AND CYCLE LENGTH |
DEGREE |
POINT VALUE |
|
| 1. Very Short | Extremely repetitive, 0 to .25 Standard Allowed Minutes | 0-1 |
| 2. Short | Highly repetitive, 0 to .50 Standard Allowed Minutes | 1-2 |
| 3. Medium | Repetitive, .51 to 1.50 Standard Allowed Minutes | 3-4 |
| 4. Long | Variable, 1.51 to 5.00 Standard Allowed Minutes | 5-6 |
| 5. Very Long | Extremely variable, over 5.00 Standard Allowed Minutes | 7-10 |
| F. | HANDLING |
DEGREE |
POINT VALUE |
|
| 1. Simple | No alignment, regular shape, easy to handle | 0-5 |
| 2. Normal | One or two alignments, regular shape, easy to handle | 6-10 |
| 3. Irregular | 3 alignments, irregular shape, hard to handle, some accuracy required on all parts | 11-15 |
| 4. Complex | 4 alignments, high accuracy required on all parts, hard to handle, | 16-20 |
| 5. Extremely Complex | More than 4 alignments, very high accuracy required on all parts, very hard to handle, | 21-25 |
| G. | EQUIPMENT |
DEGREE |
POINT VALUE |
|
| 1. None | Hand operation, no equipment required | 1 |
| 2. Simple | Trip machines | 2 |
| 3. Somewhat Difficult | Programmable Machinery, Single Needle and Overlock Machines with Needle Positioners, Undertrimmers, etc. | 2 |
| 4. Difficult | Machines with multi-operation attachments | 3 |
| 5. Complex | Off The Arm Machines w/Lap Seam Folders, Complex Multi-head Computer Assisted Machinery | 4 |
| H. | WORKER INJURY POTENTIAL . . . |
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