Title Page
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Prepared by
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Trainee Name
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Work Cell/Area
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Select training situation
Introduction
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Introduction to the department
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Walk trainee through assigned department review process flow
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Introduce trainee to area Team Leader
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Introduce trainee to area Trainer and team
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Review / explain team board / problem solving board
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Review customer demand schedule and potential overtime
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Review OJT system
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Review training plan
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Expectations
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Understand key quality aspects of job (Job specific) - Start Date
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Understand key quality aspects of job (Job specific) - Completion Date
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Know and perform autonomous maintenance and CWI process (Job specific) - Start Date
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Know and perform autonomous maintenance and CWI process (Job specific) - Completion Date
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Know and perform job within process (Job specific) - Start Date
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Know and perform job within process (Job specific) - Completion Date
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Know cycle time and build to them (Job specific) - Start Date
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Know cycle time and build to them (Job specific) - Completion Date
Operator in Training - Level 1
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Introduce trainee to rotation plan (If this pertains)
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Introduce training part / 1st off & last off boundary part (area specific)
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Introduce trainee to work cells
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Trainee to read MES / SOS (MES if applicable)
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Trainee to read JES
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Trainee watches trainer build (Time trainee watches to be determined by trainer)
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Trainee reads through SOS / JES / MES again
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Introduce trimming and flaming techniques (Molding specific)
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Section Completion Date
Builds with Trainer - Level 2
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Review training part / 1st off & last off boundary part (area specific)
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Review cycle time for station hourly rate board
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Trainee begins building in process until all steps are being performed
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Trainee will use trainers badge as their own until trainee completes level 3
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(Steps are introduced in a fashion that the cell maintains achieving posted rates)
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Section Completion Date
Builds with Quality - Level 3
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Trainee is performing all job elements, trainer no longer is required in cell
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(Team Leader can identify training partner to complete remaining steps)
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Trainee is building in process while maintaining quality expectations
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Trainer certifies each build before putting in finished goods tote or passing to next station and initials label
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Section Completion Date
Builds at Rate - Level 4
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Trainee is building 100% without trainers assistance
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Trainer can check spot trainees builds (Finished goods still flow through C30)
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Trainee no longer uses trainers badge, they are issued their own badge
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Trainee builds rate for 2 hours while maintaining process and quality
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Section Completion Date
Team Leader's Review
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Positive feedback
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Constructive feedback
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Review day's training with trainee
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Review trainers comments
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Review additional training plans (This could include same station or next assignement)
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Input OJT updates
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Trainer - Trainee has proven to build at rate while maintaining quality standards
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Trainee - Trainee is comfortable building alone, making rate while maintaining quality
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Trainee Signature
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Team Leader Signature
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Section Completion Date
Alerts
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Alert training completed prior to being placed in OJT system (List Alert Numbers)
Production Manager Sign-off
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Production Manger Name
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Production Manager Approval
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Approval Date
Introduction to Department
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Walk trainee through assigned department and review process flow
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Introduce trainee to their team and trainer
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Review and explain team P.R.I.D.E board
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Review OJT system
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Review training plan
Training Validation
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Select a program
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Select the JL FEM workstation or cell/area
- AGC ST 2
- AGC ST 3
- AGC ST 5
- AGC ST 6
- AGC ST 7
- AGC ST 10
- AGC ST 11
- AGC ST 13
- ECM SUB ASSEMBLY
- ASSEMBLY KITTING
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Select the JT FEM workstation or cell/area
- Carousel 1
- Carousel 2
- Carousel 3
- Carousel 4
- Carousel 5
- Carousel 6
- Carousel 7
- Carousel 8
- ECM Subassembly
- Assembly Kitting
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Select the JL Grille workstation or cell/area
- Station 1 (Rivet)
- Station 2 (Welder)
- Station 5
- Station 6 (Rings/W Clips)
- Station 7 (Textures)
- Station 8 (Screws)
- Poka Yoke (Hood Seal and EOL)
- Texture/Ring Kitting
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Cycle time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Select the JT Grille workstation or cell/area
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Cycle time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Select the JL Front Bumper workstation or cell/area
- FPA Assembly
- Station #1A
- Station #1B
- Station #2
- Station #3
- Station #5
- Station #6
- Station #7
- Station #8
- Packout
- Kitting
- Batch Build
- Blow Mold 1
- Blow Mold 2
- Blow Mold 3
- Blow Mold 4
- Blow Mold 5
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Cycle time (seconds)
- FPA Assembly
- Station #1A
- Station #1B
- Station #2
- Station #3
- Station #5
- Station #6
- Station #7
- Station #8
- Packout
- Kitting
- Batch Build
- Blow Mold 1
- Blow Mold 2
- Blow Mold 3
- Blow Mold 4
- Blow Mold 5
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Select the JT Front Bumper workstation or cell/area
- FPA Assembly
- Station #1A
- Station #1B
- Station #2
- Station #3
- Station #5
- Station #6
- Station #7
- Station #8
- Packout
- Kitting
- Batch Build
- Blow Mold 1
- Blow Mold 2
- Blow Mold 3
- Blow Mold 4
- Blow Mold 5
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Cycle time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Select the JL Rear Bumper workstation or cell/area
- RPA Cell
- Station #1/Kitting
- Station #3
- Station #4
- Station #5
- Station #6
- Station #7
- Packout
- Rear Blow Mold
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Cycle time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Select a press
- Press #1
- Press #2
- Press #3
- Press #4
- Press #5
- Press #6
- Press #7
- Press #8
- Press #9
- Press #10
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Program:
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Select station to audit
- Dock
- Top Hat
- Green Route
- Bumper Turret
- White Route
- FEM Turret
- JL Picker
- Blue Route
- North Driver
- JT Picker
- Pink Route
- Yellow Route
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Select station to audit
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Select a JL/JT Carrier station
- Rivnut Station 1
- Rivnut Station 2
- Turntable Station 3
- Turntable Station 4
- Turntable Station 5
- Turntable Station 6
- Compression Limiter 1
- Compression Limiter 2
- Compression Limiter 3 (LWR Rivnut)
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Cycle time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
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Cycle Time (seconds)
Pass/Fail Questions
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Where is your SOS/JES located?
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Where are your CWI sheets located?
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Do you understand what a non-conforming part is?
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Who has the authority to perform a by-pass?
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Can team member recite the process back verbally?
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What risk does double hitting a fastener with the torque gun pose?
Operator in Training - Level 1
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Introduce trainee to ergo rotation plan (If this pertains)
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Introduce training part / 1st off & last off boundary part (area specific)
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Introduce trainee to work cells
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Trainee to read MES / SOS (MES if applicable)
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Trainee to read JES
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Trainee watches trainer build for 15 minutes
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Trainee reads through SOS / JES / MES after observation period
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(Repeat previous two steps three times)
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Introduce trimming and flaming techniques (Molding specific)
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Section Completion Date
Builds with Trainer - Level 2
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Review training part / 1st off & last off boundary part (area specific)
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Review cycle time for station hourly rate board
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Trainee begins building in process with trainer assistance on all builds.
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(Steps are introduced in a fashion that the cell continues to achieve posted hourly rates)
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This process is repeated until trainee has full understanding of all of the requirements within the rotation.
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Section Completion Date
Builds with Quality - Level 3
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Trainee is performing all job elements on their own
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Trainee is building in process, following standardized work, while ensuring all quality attributes for the station are being followed.
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Trainer certifies each build before placing part in finished goods tote or passing on to the next station.
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Section Completion Date
Builds at Rate - Level 4
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Trainee is building 100% without trainers assistance
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Finished goods still flow through C30 where applicable
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Trainee successfully builds (6) parts at specified rate
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Trainee successfully builds at rate for 2 hours with zero defects
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Section Completion Date
