Knowledge. Performance. Impact.

Dealing with the Technical

Workforce Shortage Chuck Kooistra, CMRP

Sr. Vice President

The Skilled Trades Crisis

2

The most pressing issue facing North

American manufacturing is a lack of

qualified technical labor.

3

Automotive Parts Manufacturers Association

• The average age of an industrial tradesperson today is between 50 and 55.

• Canada’s industry will need 400,000 new workers within the next 10 years to replace retiring industrial trades people.

• “Automotive parts manufacturers will be unable to fill 42 percent of skilled trades positions.”

Source: APMA’s President, Gerry Fedchun

4

Skilled Trades Shortage: Estimated Timelines

When do you think your organization will face a skilled

trades shortage?

20%

10%

29%

41%

Less than 5 years

5 – 10 years

Greater than 10 years

Never

Source: Ontario Chamber of Commerce Business Survey

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Causes for Shortages of Skilled Trades Workers and Apprentices

• Skilled trades are not viewed as desirable professions, decreasing the supply of potential candidates.

• Education systems’ lack of focus on skilled trades has resulted in diminished supply of apprentices.

• Difficulty in attracting apprentices and skilled trades workers.

• Effort, time and cost to train apprentices exceeds the benefits.

Source: Ontario Chamber of Commerce Business Survey

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Skill and Knowledge Gaps Increasing

1900 2000

More Complex

Less Complex

Human Capabilities

System Complexity

Work Rules

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Changes in Workforce Culture Contribute to Problem

Doctor, Lawyer,

Executive, CEO

Machinist, Millwright,

Welder, Mechanic

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What’s more…

U.S. educational system amplifies the problem

The military pipeline is drying up

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Agenda

• Where will we find our craftspeople?

• What will they do differently?

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What Do We Need to Do Differently?

Selection

Training

Recruiting

Recruiting

Selection

Training

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Ways to Approach Combating the Expected Skilled Trades Shortage

Raising awareness of careers in skilled trades

Financial support for employers who train apprentices

Promoting the image of skilled trades

Offer training tax credit/financial assistance to employers

Develop national standards to recognized trades and promote ease of movement across the country

Adjust legislation to make apprenticing more efficient and effective

Source: Ontario Chamber of Commerce Business Survey

12

Top Organizations to Partner with to Develop/Source Skilled Trade Workers

Community colleges

Industry associations

Government-sponsored organizations

Similar companies

Source: Ontario Chamber of Commerce Business Survey

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Recruiting

Pre-recruiting – establish “partnerships” to revitalize interest in being a craftsperson.

– The U.S. sorely needs a “master craftsperson” certification

The retiring workforce will be a tremendous pool of resources for expertise and specialty projects.

Start recruiting at “non-traditional” military sites.

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A Match Made in Heaven?

• Over 13% of returning military vets are unemployed

• This issue has major White House attention

• Job training and tax dollars are available

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Selection

Hire specialty skills (i.e., hydraulics, industrial automation,

high voltage electrical).

Do not lower your hiring standards.

Be careful of antiquated nepotism rules.

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Is Your Training Effective?

• 85-90% of “corporate training” is deemed to be ineffective*

– Not timely

– Not job related

– No hands-on

– Inappropriate delivery mechanism

– Not tied to business needs and drivers

– Poor materials and/or instructor

– No accountability

Source: ASTD and ISPI

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Training

Streamline and focus internal training programs

Reliability training for technicians

Establish operator to maintenance progression systems

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Training Tips

• Structure your OJT

• Procedures are training

• Teach equipment and plant-specifics

• Craft skills training must be hands-on

• Don’t reinvent the wheel

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Training Delivery Mechanisms

• Self-Study Manuals

• Vendor Training

• Video Tapes

• Computer-Based Training (CD-ROM)

• Internet/Intranet

• Classroom and Lab

• Structured OJT

• JIT Training

Training Approach

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Equipment Specifics

• Provide equipment and process-specific training

• Don’t just teach the “generics,” teach the theory as it’s

applied to your facility

– Higher trainee comprehension and retention of subject

material

– Greater trainee motivation

– Trainees learn the systems as well as the theory

• Allows rapid application of the newly acquired skills and

knowledge to the job

OJT

• Structure Your On-the-Job Training

– “Carrying Joe’s lunchbox” is not an appropriate approach to

OJT

– Create a “checklist” of tasks to be performed

– Teach your maintenance staff how to be OJT instructors

– Break down the cultural fears about passing on information

22 22

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The Importance of “Hands-on” Training

• At least 50% of the training experience must be hands-on

• Allows for application of the theory

• Provides a “non-intimidating” environment for practicing newly acquired skills

• You can do it (check your bone yards and warehouses)

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Reliability Skills for Technicians

• Vibration Analysis

• Tribology and Fluids Analysis

• Precision Shaft Alignment

• Thermography

• Motor Current Testing

• Root Cause Failure Analysis (RCFA)

• Reliability Centered Maintenance (RCM)

• Planning and Scheduling

• Project Management Techniques

• Total Productive Maintenance (TPM)

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The Craftsperson’s Changing

Role in Reliability

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Equipment Reliability Philosophy

• Move from reactive to

proactive maintenance

• Identify and fix small

problems before they

grow

• Enable operations and

maintenance to work as a

team to reduce

breakdowns and

maximize equipment

availability

I fix it,

you run it I run it,

you fix it

Eliminate this

Behavior

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Traditional Operator and Maintenance Roles

Preventive

Maintenance

Predictive

Maintenance

Corrective

Maintenance

Operate

Inspect Product

Quality

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Future Operator and Maintenance Roles

Operate

Routine

Equipment Care

• Clean

• Lubricate

• Adjust

• Inspect

• Repair

Equipment

Care Coach

Reliability

Technician

High Tech

Technician

Maintain

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Importance of Basics

More than 80% of failures can be prevented by focusing on the

basics:

Cleaning, inspecting & monitoring

Procedures (operations, maintenance, installation)

Lubrication and alignment issues

Adjustments

Filtration

80% of costs

are related to

20% of

equipment

issues

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Equipment Care Coach

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Visual Management

Visual

Management

Just the right tools

In the most convenient places

Clean and ready for use

Building the

Foundation

Visual

Management

Just the right tools

In the most convenient places

Clean and ready for use

Building the

Foundation

Just the right tools

In the most convenient places

Clean and ready for use

Building the

Foundation

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Examples of Equipment Visual Controls

• Match marking of critical fasteners (bolts, nuts, screws, etc.)

• Gauges (Normal operating range) marked, and easily accessible for reading:

– Green – OK

– Red – Not OK

– Yellow (optional)

• Reservoir Unit Levels (normal levels)

• Pipes and hoses coded by type and directional flow

• Direction of rotation on motors, drives, pumps, etc.

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Visually Enhanced Inspections

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Visual Controls

Source: GMPT Romulus

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Visual Controls

Source: GMPT Romulus

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Visual Controls

Source: GMPT Romulus

37

Visual Controls

Electrical cable shunt - marked for tightness

Source: Unknown

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Visual Controls

Source: GMPT Romulus

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Visual Controls

Valve – tagged and marked in normal operating position.

Source: GMPT Romulus

40

Visual Controls

Source: Unknown

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Routine Equipment Care

Routine

Equipment

Care

Detecting & Preventing

Equipment Issues Daily

Operator led

• Routine checks

• Simple adjustments &

repairs

Operations-maintenance

partnership

Routine

Equipment

Care

Detecting & Preventing

Equipment Issues Daily

Operator led

• Routine checks

• Simple adjustments &

repairs

Operations-maintenance

partnership

Detecting & Preventing

Equipment Issues Daily

Operator led

• Routine checks

• Simple adjustments &

repairs

Operations-maintenance

partnership

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Routine Equipment Care

Routine

Equipment

Care

Inspection routine

focuses on detection

of abnormalities in

equipment critical

points.

Routine jointly

developed by operation and

maintenance.

Routine

Equipment

Care

Inspection routine

focuses on

of

equipment critical

points.

Routine jointly

developed by operation and

maintenance.

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Standardization – A Key to Competitiveness

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“The only way we’ll be competitive in today’s lean

environment is to standardize the way we do work, train

the (heck) out of the people, and then hold them

accountable to operate and maintain to those standards.” Bernie Fedak

-Director of Engineering, US Steel

(retired)

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Planning Process Quality Airplane

Operational

Standardization

Critical

Training

Execution

According to the

Standard

Stable

Results

Audit To the

Standard

Failure Analysis

(FA)

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Summary – Key Points

• Our recruiting, hiring, staffing, and training practices

need to change.

• Do not forget our Returning Warriors.

• The craftsperson of the future will be an Equipment

Care Coach and a Reliability Technician.

• We all have a personal responsibility and role in fixing

this problem.

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Questions and Answers

Thank you!

Chuck Kooistra, CMRP

Sr. Vice President

GP Strategies Corporation

Work 813-569-4056

Cell 813-244-5134