The document outlines a training program for machine operators at an automotive manufacturing plant. It describes a 5-level certification process where operators progress from basic skills and job orientation to independent work including training others. Lower levels involve introductory off-and on-the-job training, while higher levels focus on maintenance, problem-solving, and total productive management skills. The goal is for operators to gain expertise to work across different production lines and ensure high equipment availability, productivity, and quality.

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Submitted By:Submitted By:
Kartikey Saxena
20135029
MBA General Management
Faculty Mentor:Faculty Mentor:
Sudhir Yadav
Associate Professor
SPM, PDPU
Industry Mentor:Industry Mentor:
Mr Pranav Dave
Assistant Manager
Tata Motors, Sanand

2.  To understand how a training program is
designed.
 How to identify the contents of training.
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3.  Research Type: Exploratory and Descriptive
 Research Approach: Qualitative Research and
Quantitative Research
 Research Method: One to One Interaction,
Observation and Past Training Data
 Observation by going to every work station in four lines, namelyObservation by going to every work station in four lines, namely
Under Body (UB), Main Respot (MR), Body Complete (BC) and MainUnder Body (UB), Main Respot (MR), Body Complete (BC) and Main
Frame (MF)Frame (MF)
 Sources of Data: Primary Data and Secondary Data
 Target Sample: Machine operators and line
supervisors of weld shop
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4.  Machine operators are able to work in different
production lines with their optimum efficiency .
 To increase OEE (Overall Equipment Efficiency).
OEE = Availability * Productivity*QualityOEE = Availability * Productivity*Quality
 Availability of machines can be increased by
reducing machines break down, so training is
required for planned maintenance .
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9. New operator comes
Give basic information of line
Give him knowledge of respective area
and deploy him off the job training
under guidance of skilled trainer
(4 days)
Supervisor checks
whether the
trainee is learning
the essential skills
effectively and
now is he is ready
for on the job
training?
HRHR
Training DepartmentTraining Department
Fails extend training
for 1 day
Fails extend training
for 1 day
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10. Deploy him on the job training under
guidance of seniors for 16 weeks
Certify Level 1Certify Level 1
Supervisor
checks whether
operator follows
the basics of
maintenance and
management
system
FailFail
Certify Level 2Certify Level 2
Deploy on the job training and also to
work independently for 32 weeks
Supervisor checks
whether operator
can work
independently
with skill and
quality in time and
also with full
safety
Fails (Extend Training
for 8 weeks)
Fails (Extend Training
for 8 weeks)
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11. Deploy him on line training for 32 weeks and this
time the machine operator has to also guide new
operator and to carry all the maintenance
independently
Certify Level 3Certify Level 3
Supervisor checks
whether operator had
carried out breakdown,
preventive and periodic
maintenance
successfully, worked
safely and also have
knowledge of
management system
Certify Level 4Certify Level 4
Fail (Extend Training for
2 weeks)
Fail (Extend Training for
2 weeks)
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12. Need Analysis:
This shifting of employee requires
a thorough training program as the
operators in BC line are not familiar
to robotic and manual welding.
Need Analysis:
This shifting of employee requires
a thorough training program as the
operators in BC line are not familiar
to robotic and manual welding.
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13. Level 4 certify employee
Brief introduction of the new job
and about the machine they are
going to use
Introduction to the basic
functioning of machines and
equipments
Off the job training (Duration 1
day)
Deploy him on the job training
for 8 weeks under supervision
Supervisor
check whether
operator is able
to do job
independently
with full safety
and without any
defects
Certify Level 5 and now he can
work in any line independently
and can train others
FailFail
PassPass
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14. Need Analysis:
This shifting of employee requires a
thorough training program related to
quality test as the operators in working in
UBF and MF line are not familiar about
various quality test, which part they had
to inspect
Need Analysis:
This shifting of employee requires a
thorough training program related to
quality test as the operators in working in
UBF and MF line are not familiar about
various quality test, which part they had
to inspect
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15. Introduction to the various quality
check and the procedure for it
Introduction of various possible
defects that occurs
Introduction of various techniques
required to eliminate any defect
Deploy him on the job training for
8 weeks
Supervisor check
whether operator
is able to do job
independently
with full safety
and without any
defects and have
knowledge about
management
system
Certify Level 5 and now he can
work in any line independently
and can train others
PassPass
FailFail
Brief introduction of the new job
and about the equipments and
tools they are going to use
Level 4 certify employee
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16.  Introduction to weld shop.
 Layout and process flow in weld shop.
 Description of welding process.
 Types of process equipment used.
 Do’s and don’ts in weld shop related to safety.
 Run bar training (includes part description, glowing indicators, input
buttons)
 General lines faults and trouble shooting.
 Robot Basics
 Welding machine basics and how to do welding manually by spot gun.
 Basics of pneumatics.
 Basic tips for maintenance of machines and safety
 Introduction to LOTO
 Use of measuring instruments and tools.
 Off the job training related to robotics , welding by spot gun and its
maintenance (FOR 1 DAY) 16

17.  Identification of different energy sources, LOTO point
through EFD
 Introduction to HMI(human machine interface), only related
to basic day to day functions to which they usually come
across.
 Introduction to PLC
 Advance knowledge of their respective machines on which
they are working.
 Condition based monitoring
 Fault identification during running line.
 On the job training
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18.  Training related to Preventive, Periodic and breakdown
maintenance (class room training and then on the job
training under supervision )
 Involvement in trouble shooting procedure. It helps in
enhancing the identification and problem solving skills of
operators.
 Introduction to emergency plan knowledge.
 On the job training and evaluate whether he is able to work
independently with full safety precaution and producing the
good quality product.
 Training of ‘Problem solving techniques’.
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19.  Training related to TPM (Total Productive Management).
 Introduction to ‘Corrective maintenance’ as it helps to reduce
the frequency of the breakdown in future and ensures
maximum availability of machines.
 Training of communication.
 In depth training related to hydraulics.
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20. Operator Skill Parameters for level 5
Contents of Preventive and Predictive maintenance
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21.  CBM is essential tool for reducing Breakdown
related cost.
 A balance has to be maintained between
Preventive cost and Breakdown cost.
 TPM is effective in increasing OEE .
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