You're facing unexpected downtime in plant engineering. How can you train new staff to handle it efficiently?
Downtime doesn't have to be downtime for your skills. How do you ensure new staff are up to speed?
You're facing unexpected downtime in plant engineering. How can you train new staff to handle it efficiently?
Downtime doesn't have to be downtime for your skills. How do you ensure new staff are up to speed?
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Steps can be below Identify Training Needs: Evaluate what skills or knowledge gaps exist. Create a Training Plan: Outline objectives, schedule, and content. Include maintenance drills, safety protocols, troubleshooting exercises, and hands-on equipment training. Select Trainers: Choose experienced staff members to lead sessions. Set Up Training Sessions: Organize workshops, interactive lessons, and Practical exercises. Monitor Progress: Provide continuous feedback and support. Assess effectiveness and adjust as necessary. Document Everything: Keep records of training materials, sessions, and participant progress. Follow-Up: Conduct post-training assessments to ensure knowledge retention and application on the job.
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Firstly when you are facing unexpected downtime, we need to analyze the significance of it in terms of cost, time and resources. I believe that, it is better that someone who is experienced need to handle that situation. The only way is to provide on job training by the experienced person who is going to resolve that issue. By this way you will be benefitted in both ways.
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To train new staff, consider these strategies: 1. Training & skill development: Provide thorough onboarding training on equipment, processes, & common downtime issues. 2. Brainstorming & RCA : Train them on recurring downtime by engaging in previous root causes using FMEA, 5W1H etc. 3. Simulations & Drills: Conduct regular drills simulating downtime scenarios to practice quick responses and problem-solving. 4. Collaboration & Mentorship: Pair new staff with experienced employees for guidance training & Foster a team culture where staff can seek help. 5.Maintenance: Create accessible manuals outlining troubleshooting steps and maintenance procedures. 6.Feedback Loop: Implement a system to share feedback for continuous improvement.
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Normally We experience Down time Due Unexpected Behaviour of the machines and resources In TQM we have a too called as Daily Work Management which ensures "Things to do on Daily Basis" by team It includes Direct,Middle and top Leadership daily jobs on the shop floor which might be in terms of Audits,Check points and Records In parellal when we Implement AI for the Machine Performnace,We will have real time data and DWM will help us to find out Real root causes of Down time This way will lead for more engagement with the Situation and will lead collaboarative efforts for reducing the unexpected Down times Thank You
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Training New Staff for Unexpected Downtime: Strategy 1. Documented Procedures 2. Simulation Training 3. Mentorship 4. Regular Drills 5. RCA Training 6. Communication Protocols 7. Continuous Learning Key Competencies 1. Problem-solving 2. Decision-making 3. Communication 4. Time Management 5. Collaboration Training Methods 1. Classroom 2. On-the-job 3. Virtual Reality 4. Case Studies 5. Hands-on Evaluation 1. Performance Assessment 2. Feedback 3. Peer Review Benefits 1. Reduced Downtime 2. Improved Response 3. Enhanced Performance 4. Increased Safety 5. Knowledge Retention By implementing these strategies, new staff will efficiently handle unexpected downtime, minimizing production losses.
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By use a combination of technical training, real-life scenarios, and troubleshooting exercises. Here are a few strategies: 1. Root Cause Analysis Training: Teach them how to quickly identify and analyze the root causes of downtime. Use historical cases and current systems to demonstrate common issues, so they can learn to diagnose problems accurately. 2. Emergency Response Drills: Run mock downtime scenarios where new staff must apply their skills to resolve issues under time constraints. This prepares them for the pressure of real downtime situations and builds their confidence.
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Proactive resources alongwith Transparancy with all teams like Supply, installation, testing & commissioning with maintenance will ensure to enhance timely productivity. This coarse of action plan of each KRA of an individual,skill team leaders, area leaders to be planned since inception to system operation.
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If there is any unexpected Down time that occurs, we need to analyse new staff through the point 1. How much time is taken for the response of down time 2. How many times taken for analysis of identification of down time category 3. How many times have you taken for close the issue. 4. If the issue is not solved then, How many times taken for down time reporting. So according to all 4 points we need to create a SOP for Down time handling. In this SOP for all processes we should be defined as the time duration of all activities. Like - For point number 1, Staff should be attending the issue within 2 Mins. After that we should be ensured the following of SOP. if it's followed, Down Time should be less.
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Downtime may not just come from the skills of the workers. It can also happen due to factors like people, methods, machines, materials, or the environment. It’s important to find the main cause of the downtime before deciding how to fix it. If you find that downtime is related to worker skills, using a skill matrix can help. A skill matrix shows you what your team can do and helps identify skill gaps. Make sure your team has a mix of highly skilled workers and those with lower skills for effective operations. Encourage training for less experienced team members while they work, so they can learn on the job. Also, provide offline training for those who are not currently working to ensure everyone is ready to help reduce downtime.
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Following steps should be taken to train the staff in reducing downtime: 1. Give them a list of do's & don'ts for the machineries. 2. Train them to do the 5s' of machines, follow the check sheets on daily basis. 3. Give them hands on training to carry out preventive maintenence on a regular basis. 4. Ensure that all staff understand the machinery, including optimal operational parameters and failure modes. 5. They should be trained to properly read the process documents such as control plan, work instruction and make them understand the importance of SOPs.
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