3.4 Step 4: Establish Systems to Further Develop and Enhance Abilities
3.4.1 Link to Autonomous Maintenance Step 4
It is best to combine technical operating skills training with the training given at Step 4 of the Autonomous Maintenance programme.
3.4.2 The role of managers
(1) Secure the funds needed for technical training
(2) Review the company’s technical training programme and emphasize the importance of people development.
3.4.3 Key points for training to improve people’s ability to get the job done
The training and development programme should be based on on-the-job training and self-development. Training and development plans should take account of the needs of the individual.
(1) It is important to establish what skills, knowledge and qualifications are needed for the job, devise a training plan that takes into account the development needs of the individual, and carry out regular assessments as the course progresses.
(2) Personal training and development plans should be implemented systematically in accordance with a system like that shown in Table 9.2 – 9.5, using a combination of on-the-job training, self-development and off-the-job training.
3.5 Step 5: Create an Environment that Encourages Self-Development
Every company should create a training environment suited to its needs, with distance learning, video training, literature, assistance with funding and other training opportunities made available to employees. All employees should be assigned a new self-development topic every six months, and progress against targets should be monitored. They should also be given the chance to acquire nationally recognised qualifications. Operators’ Autonomous Maintenance skill levels should be raised by encouraging them to study for tests such as the JIPM’s Autonomous Maintenance Practitioner Test.
3.6 Step 6: Evaluate Programme So Far, and Decide on Future Direction
Regularly evaluate progress made against the training plans to see how well the necessary skills are being developed in individuals in every type of job and at each level of the organisation. Technology, equipment and management approaches are advancing day by day, and the company’s training and development programme must keep pace with and even anticipate these changes. This makes it essential to continually monitor the contents of the programme and the results it is producing, supplementing and enhancing it wherever necessary.
Subjects, Main Topics and Sub-Topics of Written Examination
Table 9.6 Autonomous Maintenance Practitioner Test Curriculum
N/A – not applicable
Overview – outline knowledge (true/false) General – general knowledge (4-choice)
Detail – detailed knowledge (fill in the blanks)
Subjects and Main Topics of Practical Examination
4. Important considerations regarding training
4.1 Conducting In-House Skills Training
4.1.1 Developing in-house instructors
(1) Setting the curriculum
The first thing to do is to establish the curriculum by looking at the equipment the company possesses and deciding on the level of skill the trainees will need, what should be taught, and how long should be spent teaching it.
(2) Preparing lesson plans
1 If training is to be effective, the trainees must be made to study the material for themselves until they have mastered it.
2 Highly practical lesson plans tailored to the company’s particular requirements should be prepared for each item to be taught.
3 The most important thing is to prepare in-house textbooks that will permit self-study
4 Prepare practical training materials (see photographs on Page 9-14), cut-away models, etc. It is particularly important to prepare sufficient materials for each person to be able to perform the practical training individually. Expensive equipment such as transmissions, lubrication systems and control devices can be shared between 2-3 trainees.
5 A permanent skill training centre should be provided.
6 Classrooms should also be set up.
It is important for the training to be carried out on a one-to-one basis, with 6-10 trainees per class being the best number. An environment conducive to study, with space to accommodate training rigs, should be arranged.
When developing skilled people able to handle sophisticated equipment, the important thing is not so much to teach them but rather to provide an environment that motivates them to learn for themselves (see Figures 9.10 and 9.11).
Figure 9.10 Pattern for Self-Study
Figure 9.11 Layout for Training
Figure 9.12 A Theory of Motivation
Figure 9.13 What is Teaching?