The document discusses a report analyzing certification processes for departments 40 and 45 at Timken Company's Bucyrus Bearing Operations. It found many associates were overdue for certification, some by two years. Key personnel were polled and overwhelmingly felt current certification programs were inadequate. The report suggests tracking certifications in a database and scheduling them on associates' birthdays to keep records up to date. It also recommends designating trainers and holding them accountable for associates' training and certification.

1. By Scott A. Ekleberry

2. The purpose of this report was to
investigate new ways for the Timken
Company, Bucyrus Bearing
Operations, to administer and
schedule certification of personal in
Department 40 and 45.
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3.  Certification data was collected.
 Overdue certifications mapped-out.
 Key personnel were polled for input.
 The impact of department vacation on
timely certification was explored.
 Alternative methods considered for the
certification process.
 Final analysis of certification process
and alternatives laid out.
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4. 1/10/2013 Scott A. Ekleberry 4

5. 1/10/2013 Scott A. Ekleberry 5

6. The certification process in place
for Departments 40 and 45, is just
not working. Countless associates
are overdue for certification, some
as much as two years or more.
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7. Inspectors Overdue for Certification
Total Inspectors
0 10 20 30 40 50 60 70
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8. Total Number of LMA Overdue for
Certification
Total Number of LMA
0 5 10 15 20
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9. Total Cone MA's Overdue for
Certification
Total Number of Cone MA's
0 20 40 60 80 100
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10. 1/10/2013 Scott A. Ekleberry 10

11.  Do you feel there is a problem with the way training
or recertification is handled in your department?
 Do you feel that scheduling training/recertification
on (or near) the associate’s birthday would help in
keeping certifications current?
 Do you feel that a lack of proper training is a problem
in your department?
 Do you feel scheduling brush-up training on (or near)
the associate’s birthday would be an asset?
 Do you feel there is a problem completing
certifications and training during the summer months
due to vacations schedules?
 Do you feel that the present certification and training
programs are adequate?
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12. 100% of respondents felt
that training and
certification were not
handled well in
Departments 40 and 45
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13. Do you feel that the present certification and
training programs are adequate?
Yes
17%
No
83%
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14. Do you feel that scheduling certification on
(or near) the associate’s birthday would help
in keeping certifications current?
No
33%
Yes
67%
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15. Do you feel that a lack of proper training is a
problem in your department?
No
17%
Yes
83%
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16. Do you feel scheduling brush-up training on (or
near) the associate’s birthday would be an asset?
No Yes
50% 50%
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17. Do you feel there is a problem completing
certifications and training during the summer
months due to vacations schedules?
Yes
67%
No
33%
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18. Do you feel that the present
certification and training programs
are adequate?
Yes
No 17%
83%
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20. “The LMA on each line should
be responsible for certification
of each MA on their line, since
they work with them and
should know what additional
training they need, if any.”
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21. “Training methods and ability is
not consistent from trainer to
trainer.”
“Training and certifications
should be verified by more than
one trainer, especially in
recertification's.”
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22. “Training methods and ability is
not consistent from trainer to
trainer.”
“Training and certifications
should be verified by more than
one trainer (especially in
recertification's).”
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23. “One person should be designated the sole
trainer for each operation, and stick with that
person; in this way, each person trained has the
same information and training.”
“Each instructor should have the ability to
disqualify someone, and the company should
respect the judgment of the instructor.”
“Each trainer should be solely responsible for
keeping records of training and certification. The
training department should take a leadership roll
in training.”
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24. “We need proper trainers.”
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25. “We need a full-time trainer on each shift who will be held
accountable for proper training; management should stand
behind this trainers decision of "pass" or "fail".”
“Have the LMA do recertification's, and have the supervisors
verify this; inspectors should self re-test using an on-line test. “
“The instructor should be with new associates for two weeks
in the line assignment the associate will be assigned to. Leave
the associate to prove knowledge, with LMA, for two
weeks, before certifying or moving to next operation.”
“Hold trainer accountable for knowledge, once trained
associate should be able to change over machines in allotted
time frame, or instructor should have a good reason why they
cannot.”
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26. Number of Associates on Vacation
20
10
0
Number of Associates
January
February
March
April
on Vacation
May
June
July
August
September
October
November
December
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27. Number of Associates on Vacation
15
10
5
0
Number of Associates
January
February
March
on Vacation
April
May
June
July
August
September
October
November
December
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28. 1/10/2013 Scott A. Ekleberry 28

29. Track Certifications using a database and
spreadsheet system. Trainers or managers
need only update the spreadsheet with the
next certification date for each
associate, the database will automatically
track the needed certifications from that
point on. The same method could be used
for needed training, but clearly, the
certification situation needs to be
addressed first.
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30. Schedule certification on, or
around, the associates birth date.
This will make it very easy to
update the spreadsheet record
once the new certification process
is in place.
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31. Explore the possibility of the Timken IT
Department designing an interface with
the supplied Access Database which will
automatically e-mail supervisors reports of
associates due for certification on a weekly
basis. This would eliminate the manager
having to make reports from the database
and e-mail them to supervisors.
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32. It is felt that the new database/spreadsheet
system is a viable means of tracking
certifications easily and accurately. For most
effective use, the spreadsheet and database
should be placed in a folder on the server, so that
they may be easily accessed and updated.
As with any system, this one will only be as
effective as those that are assigned to update the
files on a regular basis.
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