Samples and Examples
Sample TeamOJT Training Modules
The following excerpts from actual training modules illustrate the simplicity of format and flexibility of the system that allows teams to add their own flair and uniqueness. One sample shows a training module that is embedded in a Standard Operating Procedure (SOP) - a simple cut and paste operation.
Nestle Chocolate and Confections
Nestle was planning to open a new ammonia refrigeration plant at one of its East Coast facilities. The electrical engineering manager in charge of the new plant was, in his words, "getting a little desperate."
"I'm looking for some way to come into compliance with process safety management, which is an OSHA mandate," he said. "We don't have a process for doing that. And we received only two paragraphs of information from the manufacturer."
HPA conducted the TeamOJT Workshop for Nestle managers, training directors, training managers, supervisors, and human resources personnel. Immediately after the workshop, the engineering manager formed a team of employees who would work in the new ammonia refrigeration plant. The team quickly grasped the simple two-question technique for conducting the team job task analysis and within the first hour identified 18 safety-related tasks that needed to be trained before they could put the charged liquid ammonia into the system. Then after being introduced to the easy-to-read-and-use two-column format for writing training modules, the team members started writing. The team met one-two hours per week. After only six weeks, the plant was up and running, safely having put 26,000 pounds of anhydrous ammonia into the system and having completed an additional 25 training modules on equipment operation. In addition, they had trained eighteen employees to run the new system! And months ahead of schedule!
Today, several of the company's plants in the United States and Canada have implemented this team-based approach. Training managers, safety experts, and corporate executives from all over the world have learned the TeamOJT model. It has become a company-wide "best practice." OSHA has consistently been impressed with the training modules and procedures for "their clarity, consistency, ease-of-use, and simple format that permits easy and frequent updates." They have even asked Nestle for training modules to use as models for other companies.
At its largest maintenance facility, Northwest Airlines had received eight engines for what should have been normal repairs over an eight-month period. The engines, however, were shipped improperly, which necessitated complete engine tear-downs instead of the routine repairs. The average cost of engine repairs at the time was $500,000. The average cost of complete engine tear-downs was $2.2 million. The potential cost of mishandling was $13.6 million per year. The solution to the problem turned out to be quite simple. The airline's maintenance teams had all been trained in TeamOJT and were actively engaged in developing training modules on identified tasks. During one of their module writing sessions, a team of engine mechanics noted the problem regarding the engine repairs and started discussing possible solutions. They were able to quickly devise a new method to secure the engines before shipping. The team wrote two training modules on how to ship the engines, verified and approved them, and via the company intranet sent the training modules to the three stations around the world that were involved in shipping those engines. Training began the very next day at each location. During a one-year period following the training, there were no more occurrences of engine damage from shipping - a savings of over $13 million dollars!
The short time invested by this team--less than three hours to write, verify, and approve the two training modules--made a tremendous impact on the airline's bottom line. And the employees were beaming with pride. Without this type of information sharing and discussion of performance issues that occurs naturally as teams examine how best to do the job, this huge cost-saving solution might never have happened. Today, TeamOJT is being implemented throughout the airline's maintenance and ground operations division in bases around the world.
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