THE CHALLENGE

MAGNET did a Needs Assessment Analysis for Lorain Pipe Mills and discovered Operator-level training was needed at the plant. During the analysis, MAGNET consultants also found that most of the highly skilled workers at the plant were approaching retirement age. This presented a problem because training materials and vendors no longer existed for the plant’s long standing equipment. Most training was conducted in a hands-on environment with each operator utilizing his own set of specialized techniques. Because of this, running the equipment had become more of a craft than a skill with the ability to troubleshoot on the machines a necessity. The company needed a vehicle to enable a knowledge transfer of operation techniques currently being used to the next generation of skilled workers at the plant.

THE APPROACH

The first step in the project was to tackle a key operation in the production process, the Reelers. In the reeling operation, the pipe’s inside and outside surfaces are smoothed out to eliminate surface imperfections. The three phases of set-up, general operation and corrective action needed to be documented. To do this, MAGNET consultants needed to capture the experience and knowledge of the current workforce and relied heavily on the experience of a group of Lorain Pipe Mill managers and USWA represented operators. With over 200 years combined experience, these operators provided a great deal of input for the training material. Operations were documented through written instructions, videotape and photography.

From this input and documentation, MAGNET consultants made a written manual to be used for training purposes and as a point of reference for the current operators. In addition to the manual, a multi media, computer-based training program was developed. The material was very customized and interactive, enabling workers to complete the training at their own pace. Vivid graphics and knowledge checks also were included.

The new training material has not only captured the experience of the Lorain Pipe Mills current workforce, enabling future knowledge transfers, but has also enabled more effective cross training at the plant, improving productivity and quality.

CUSTOMER QUOTE

"MAGNET employs great consultants and project managers that push us just enough to keep the project moving. They’re not afraid to ‘tell us like it is’. Their ideas came from the real world and have practical application. These efforts helped us achieve $500,000 savings on labor efforts and significant reductions in scrap." Rick Mahon
Manager Employee Relations

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