Dabur
Dabur
Dabur
Submitted in partial fulfillment of the requirements For the award of the degree of BBA
Under the guidance of Mr. Keshav Kr. Gupta (Assistant Professor) Mrs. Sakshi Vashisht (Assistant Professor) Submitted by Manav Nagpal O6621001709 Ideal Institute of Management and Technology, Delhi Affiliated to Guru Gobind Singh Indraprastha University
Guide Certificate
This is to certify that Manav Nagpal persuing BBA from Ideal Institute of Management and Technology has completed his project under my guidance and supervision. He has taken care if all necessary aspects and own interest and sincerity during the completion of project file to my full satisfaction. I certify that the project is upto my expectations as per the guidance laid down by the Guru Gobind Singh Indraprastha University.
Mr. Keshav Kr. Gupta (Assistant Professor) (IIMT ) Mrs. Sakshi Vashisht (Assistant Professor) (IIMT )
ACKNOWLEDGEMENT
First of all I would like to take this opportunity to thank Mr. A. Sudhakar Asst. HR Manager of Dabur India Ltd., Ghaziabad, who was very generous in giving me this opportunity to work under his kind guidance, where he made me so comfortable in working and providing me valuable guidance out of his busy schedule. Further I would like to thank all the staff members of HR division who have been very courteous in providing all the other information about the company and its products.
(MANAV NAGPAL)
DECLARATION
I Hereby Declare That the Research Project Report Entitled STUDY OF TRAINING AND DEVELOPMENT IN HR AT DABUR INDIA LTD submitted in partial fulfillment of 'BACHELOR OF BUSINESS ADMINISTRATION' is of my original work and not submitted for the award of any other Degree, Diploma, Fellowship or other similar TITLE or PRIZE.
EXECUTIVE SUMMARY
Topic of study:
A comprehensive study of Training & Development programs that has been carried out at Dabur India Ltd., Sahibabad.
i.
ii.
Preliminary discussion:
In this regard at the outset, I would like to talk about the training and development in charge to enquire for the identify the needs of training and development programs at present scenario.
iii.
Feedback from the employees through the interview and written questionnaire.
For evaluation the effectiveness of training and development programs I would like to take feedback from employees that how much they get benefit from that program. At last I would like to take suggestion for future improvement.
CONTENT
CHAPTER - 1 1. Company Profile CHAPTER - 2 2. Introduction
Training Development Policy Training Need Identification Methodology of Training
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Skill training 5s Training Evaluation of training & Development Objective CHAPTER - 3 3. Methods of Training in Company 79 80-93 94-96 97-99 100 CHAPTER - 4 4. Data Analysis & Interpretation CHAPTER - 5 5. Suggestions & Limitations CHAPTER - 6 6. Annexure CHAPTER -7 7. Bibliography
Early 1900s - Production of Ayurvedic medicines Dabur identifies nature-based Ayurvedic medicines as its area of specialisation. It is the first Company to provide health care through scientifically tested and automated production of formulations based on our traditional science. 1930 Automation and up gradation of Ayurvedic products manufacturing initiated 1936 - Dabur (Dr. S K Burman) Pvt. Ltd. Incorporated 1940 Personal care through Ayurveda Dabur introduces Indian consumers to personal care through Ayurveda, with the launch of Dabur Amla Hair Oil. So popular is the product that it becomes the largest selling hair oil brand in India. 1949 Launched Dabur Chyawanprash in tin pack Widening the popularity and usage of traditional Ayurvedic products continues. The ancient restorative Chyawanprash is launched in packaged form, and becomes the first branded Chyawanprash in India. 1957 - Computerization of operations initiated 1970 Entered Oral Care & Digestive segment Addressing rural markets where homemade oral care is more popular than multinational brands, Dabur introduces Lal Dant Manjan. With this a conveniently packaged herbal toothpowder is made available at affordable costs to the masses. 1972 Shifts base to Delhi from Calcutta
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1978 Launches Hajmola tablet Dabur continues to make innovative products based on traditional formulations that can provide holistic care in our daily life. An Ayurvedic medicine used as a digestive aid is branded and launched as the popular Hajmola tablet. 1979 - Dabur Research Foundation set up 1979 - Commercial production starts at Sahibabad (U.P.), the most modern herbal medicines plant at that time 1984 - Dabur completes 100 years 1988 Launches pharmaceutical medicines 1989 - Care with fun The Ayurvedic digestive formulation is converted into children's fun product with the launch of Hajmola Candy. In an innovative move, a curative product is converted to a confectionery item for wider usage. 1994 - Comes out with first public issue 1994 - Enters oncology segment 1994 - Leadership in health care Dabur establishes its leadership in health care as one of only two companies worldwide to launch the anti-cancer drug Intaxel (Paclitaxel). Dabur Research Foundation develops an Ecofriendly process to extract the drug from its plant source 1996 - Enters foods business with the launch of Real Fruit Juice
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1998 - Burman family hands over management of the company to professionals 2000 - The 1,000 crore mark Dabur establishes its market leadership status by staging a turnover of Rs.1000 corers. Across a span of over 100 years, Dabur has grown from a small beginning based on traditional health care. To a commanding position amongst an august league of large corporate businesses. 2001 - Super specialty drugs with the setting up of Dabur Oncology's sterile cytotoxic facility, the Company gains entry into the highly specialised area of cancer therapy. The state-of-the-art plant and laboratory in the UK have approval from the MCA of UK. They follow FDA guidelines for production of drugs specifically for European and American markets. 2002 - Dabur record sales of Rs 1163.19 crore on a net profit of Rs 64.4 crore 2003 - Dabur demerges Pharmaceuticals business
CORE VALUES
Ownership: This is our company. We accept personal responsibility, and accountability to meet business needs Passion For Winning: We all are leaders in our area of responsibility, with a deep commitment to deliver results. We are determined to be the best at doing what matters most People Development: People are our most important asset. We add value through result driven training, and we encourage & reward excellence Consumer Focus: We have superior understanding of consumer needs and develop products to fulfill them better
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Team Work: We work together on the principle of mutual trust & transparency in a boundaryless organization. We are intellectually honest in advocating proposals, including recognizing risks Innovation: Continuous innovation in products & processes is the basis of our success Integrity: We are committed to the achievement of business success with integrity. We are honest with consumers, with business partners and with each other
DABUR AT A GLANCE
Dabur India Limited has marked its presence with some very significant achievements and today commands a market leadership status. Our story of success is based on dedication to nature, corporate and process hygiene, dynamic leadership and commitment to our partners and stakeholders. The results of our policies and initiatives speak for themselves.
Leading consumer goods company in India with 4th largest turnover of Rs.1163.2 Crore (FY02)
3 major strategic business units (SBU) - Family Products Division (FPD), Health Care Products Division (HCPD) and Dabur Ayurvedic Specialties (DASL)
5 Subsidiary Group companies Dabur Foods, Dabur Nepal, Dabur Oncology, Dabur Pharma and Dabur Egypt
13 ultra-modern manufacturing units spread across 4 countries Products marketed in over 50 countries
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Wide and deep market penetration with 47 C&F agents, more than 5000 distributors and over 1.5 million retail outlets all over India
FPD, dealing with personal care, the largest SBU contributing to 45% sales of Dabur Products related to Hair Care, Skin Care, Oral Care and Foods 3 leading brands - Vatika, Amla Hair Oil and Lal Dant Manjan with Rs.100 crore turnover each Vatika Hair Oil & Shampoo the high growth brand Strategic positioning of Honey as food product, leading to market leadership (over 40%) in branded honey market HCPD, dealing with daily health care, 2nd largest SBU with 28% share in sales
Products related to Health Supplements, Digestives, Baby Care and Natural Cures Leadership in Ayurvedic and herbal products market with highly popular brands Dabur Chyawanprash the largest selling Ayurvedic medicine with 65% (Rs.127 crore) market share.
Charted high growth with 15% in 2001. Dabur Chyawanprash and Hajmola account for sales of over Rs.100 crore each Leader in herbal digestives with 90% market share Hajmola tablets in command with 75% market share of digestive tablets category
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Dabur Lal Tail tops baby massage oil market with 35% of total share
DASL, dealing with classical Ayurvedic medicines Has more than 250 products sold through prescriptions as well as over the counter Major categories in traditional formulations include -Asav Arishtas Ras Rasayanas Churnas - Medicated Oils Proprietary Ayurvedic medicines developed by Dabur include: -Nature Care Isabgol Madhuvaani - Trifgol
Dabur's mission of popularizing a natural lifestyle transcends national boundaries. Today there is global awareness of alternative medicine, nature-based and holistic lifestyles and an interest in herbal products. Dabur has been in the forefront of popularizing this alternative way of life, marketing its products in more than 50 countries all over the world.
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Dabur have spread itself wide and deep to be in close touch with our overseas consumers.
Offices and representatives in Europe, America and Africa; A special herbal health care and personal care range successfully selling in markets of the Middle East, Far East and several European countries.
Inroads into European and American markets that have good potential due to resurgence of the back-to-nature movement.
Export of Active Pharmaceutical Ingredients (APIs), manufactured under strict international quality benchmarks, to Europe, Latin America, Africa, and other Asian countries.
Export of food and textile grade natural gums, extracted from traditional plant sources.
Strategic partnerships with leading multinational food and health care companies to introduce innovations in products and services.
Manufacturing facilities spread across 3 overseas locations to optimize production by utilizing local resources and the most modern technology available.
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*Amla Hair Oil *Amla Lite Hair Oil *Vatika Hair Oil *Anmol
Cooking *Coconut
Oral Care *Gripe Water *Dabur Red Toothpaste *Dabur Lal Dant Manjan *Binaca Tooth Paste
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Baby Care *Dabur Lal Tail *Dabur Baby Olive Oil *Dabur Janma Ghuti
OTC Products *Nature Care *Sat Isabgol *Shilajit *Ring Ring *Itch Care *Back Aid *Shankha Pushpi *Dabur Balm *Sarbyna
Oncology *Intaxel
*Daxotel
*Kemocarb
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*Mahanarayan Tail *Juritap *Madhuvani *Shilajit *Lavan Bhaskar Churna Oral Care *Herbal Toothpaste Hair Care
*Honey *Vinelbine
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CHAPTER - 2 INTRODUCTION
TRAINING & DEVELOPMENT POLICY
Why training is important Every company should be fully committed to the continuous development of its staff, in the same ways as we continuously develop our services. This will be achieved by helping all staff identify and meet their own job and business related development needs. This policy will ensure that we have the adaptability and flexibility to thrive and succeed as a business. To do this, all line managers, through the Performance Review process, will Ensure that staff have a level of knowledge and skill to fully perform their role Encourage staff to develop within their current role Look for potential, and find ways for staff to demonstrate potential Recognize and reward staff development (utilizing it wherever possible) Create a learning culture by providing opportunities for learning Equal opportunities All staff are entitled to and can expect to receive training they need to carry out their current role. This includes fixed-term contract or short-term contract staff. Permanent employees can expect to benefit from further commitment for each individual to devote at least 5 days a year towards training and development. First priority will be towards job-related training, but we will also encourage individuals to undertake personal development training. This may entail taking professional qualifications;
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undertaking research into a particular field of interest or experiencing a particular aspect of another job in order to gain an insight into the role and fuller understanding of the work. Training should not be viewed purely as attending a training course. There are a variety of different methods that can be used to help train and develop individuals and Personnel Services will be happy to help individuals and managers select the most appropriate method. For-example, using open learning materials; computer-based packages; videos or CD-ROMs; e-learning; and reading literature, to name but a few.
Shared responsibilities
It is recognizes the need for everyone to learn and develop their skills on a continuous basis and will support individuals to help them achieve this. Equally, the company expects individuals to take on some responsibility for their own self-development. For example, identifying suitable training activities (with the help of line managers and Personnel Services) and adopting a flexible and positive approach to any training and development that is identified with them.
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objectives, these should be recorded on the Development Needs Assessment plan, which forms part of our Performance Review process.
individuals need to learn in order to achieve business objectives, it is important that any training and development in which we invest has a relationship to our business objectives, so we can demonstrate the contribution learning makes towards overall organizational success. To demonstrate this contribution, individuals will agree with their line managers, prior to undertaking a learning activity, learning objectives. Learning objectives will be the means by which managers and company can measure how effective training and development has been towards achieving our business objectives or performance. Setting learning objectives will therefore provide a benefit for everyone: For individuals, objectives give a better understanding of what is expected of them; where priorities lie; where their contribution fits into the organization and how they are progressing. For managers, objectives provide a basis for allocating responsibility to individuals for achieving certain results; monitoring the achievement of results and providing solid evidence, which is less subjective, for assessing an individuals performance. For the organization, objectives give a greater likelihood of strategic and corporate plans being achieved. Once someone has experienced a training and development activity or learning, we will measure its impact and effectiveness on individual performance and the organization. Again, line managers are expected to be part of this process by defining the performance
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standards (or measures) when setting objectives and deciding on the methods that they will use to evaluate the learning.(Personnel Services will of course be available throughout the process to provide guidance and support). There are three key stages that will be used to evaluate training and development: Reaction: At this level, evaluation provides information on the attitudes of a participant to learning, but it does not measure how much they have actually learned. That being said, if a participant has a positive reaction to the learning experience they are more likely to implement what they have learned. Evaluation at this level will be measured by a post-
learning questionnaire, which will be completed immediately after the learning activity has taken place. questionnaire. Performance: Evaluation at this level looks at the impact of a learning experience on individual performance at work. Key to this area of evaluation will be the need to have established smart learning objectives prior to the learning experience so that when evaluation takes place there are measures to use. For example, an important learning objective for a junior secretary attending a Word training course may be to produce typed correspondence with no spelling or typographical errors. In this example, a manager would be able to evaluate the secretarys performance using a measure of no spelling or typographical errors. Ideally, evaluation on performance should take place approximately 3 4 months after the learning activity. Line managers should undertake this evaluation and send a copy of the results to Personnel Services. Organizational impact: At this level evaluation assesses the impact of learning on Normally, Personnel Services will be responsible for issuing this type of
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Personnel Services will undertake this evaluation as part of a wider training and development evaluation process. In summary then, Personnel Services will evaluate training and development at the reaction and organizational levels, and line managers will be responsible for evaluating the effectiveness of training and development at the performance level. However, there will be some types of learning activities, for example attending conferences or seminars, where it may not be appropriate to undertake any evaluation. If any doubt, please contact Personnel Services. To assist line managers, there are a variety of methods that can be used to measure the effectiveness of the learning. Some of these include: Participant self-assessment Written or practical tests Structured interviews Questionnaires Feedback for example, internally from colleagues, peers, and managers and/or externally from partners, customers or clients Qualifications obtained
Line managers should contact Personnel Services, who will be pleased to help set-up an evaluation method to use to measure the effectiveness of a training activity.
Funding
Funding for training and development will be paid from a central training budget, therefore the Head of Personnel Services must approve any training and development that involves a
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financial cost before any financial commitment is made. Details of how to apply for a training and development are explained under the section headed Selecting a training
established a company sponsorship scheme whereby full or partial sponsorship will be provided. Information about the scheme can be found under the section headed Company sponsorship.
lectures/workshops/summer school will be agreed on an individual basis, taking account of the business needs. The Head of Personnel Services will approve any such requests, in full consultation with line managers.
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training package; on-the job training; reading books; undertaking research or practising a particular skill.
Company sponsorship
Company recognises the need for continuous professional development and are pleased to be able to offer a sponsorship scheme to all permanent and fixed-term employees (whose contracts are for at least one year). The scheme covers professional, academic or NVQ (or equivalent) qualifications. The following guidelines are designed to give
individuals an idea of the sort of funding that may be available and how individuals may apply.
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3. Conduct a complete review of legislated training requirements 4. Review the results of Hazard Analyses, Occupational Health surveys and other survey or process analyses.
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Identification of an individuals needs has been a result of the question what sort of training do you want? Effective training and development in an organization depends on the need for the improvement of human performance being identified and satisfied by the provision of appropriate development opportunities. Wants can frequently be need, but the analyst must be certain of the value of any aspect raised and eventually provided. ITN is as important in the training process as the training itself and subsequent evaluation.
ADVANTAGE OF ITN
It pinpoints the problems It identifies the size of the problem It identifies the scale of the need It indicate the type of solution It provides training objectives
DISADVANTAGE OF ITN
The list of disadvantages is considerably smaller than the benefits of advantages. The only one of any significance is the need for a skilled person to be employed and consequently the use of that persons time. This has been quoted earlier as one of the common criticisms of ITNs. If the trainer alone is responsible for conducting the analysis in addition to all the other areas of work for which they are responsible, this may be a justifiable criticism. Organization open to criticisms of over-uses and wastes of money spent on unnecessary training. So every attempt must be made to identify and analyze the needs accurately. Identification of Training needs (ITN) is the examination or diagnostic portion of the training system, the symptoms that ITN examines are often referred to as perceived
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performance deficiencies. A perceived performance deficiency exists when there is a difference between expected and perceived job performance. A ITN can be categorized based upon whether it is reactive or proactive. A reactive. ITN occurs when the perceived performance deficiency is a discrepancy between perceived and expected performance for the employees current job. A proactive ITN is conducted o respond to the perception that current job behavior reflects an inability to meet future standards or expectations. The preventive approach is designed to assure that an employee will be able to meet future expectations for his or her current job. The second is development approach. This is conducted when current job behavior leads to the perception that the individual has the potential but is not yet ready to perform at a higher level position. A proactive ITN rests on the ability of someone to predict anticipate a future problem. It may survey trainees to identity specific topics about which they want to learn more. Another HR-approach is task identification. Trainers begin by evaluating the job description to identity the salient tasks the job requires. Production records, quality control reports, grievances, safety reports, absenteeism and turnover statistics, and exit interviews of departing employees may reveal problems that should be addressed through training and development efforts. Training needs also may become apparent from career planning discussions or performance appraisal reviews. Supervisors see employees on daily basis and thus are another source of recommendations for training. The HR department also reviews self-nominations to learn whether the training actually is needed. Self-nomination appears to be less common for training situations but more commons for development activities. A job analysis should focus on what the trainee needs to be able to do to perform the job satisfactorily. In ITN, a job analysis should take both a worker and task oriented
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approach. A worker oriented approach focuses on the skills, knowledge and ability to perform the job. These might include elementary notions, job demands, and the specific human behaviors involved such as division making, communication etc. a task oriented approach focuses on a description of the work activities performed. These are typically expressed in terminology used by job incumbents an would involve a description of how, why, and/of when a worker performs an activities preferred to as a job description.
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To make learning opportunities effective and attractive. This is what training design and delivery and implementation are about
To keep a constant check on how far this match is being effectively continued. This is what training needs evaluation is about.
To keep a constant check on how far this match is being effectively continued. This is what training evaluation is about.
We need good ITN processes in order to provide then learning opportunities required achieving the goals of the organisations.
The training need was about learning to question the way we do things. The solution was not direct training in questioning, but a subtler longer-term process of encouraging employees to take an active involvement in their own development, thus increasing their commitment to learning, to their work, and to the organization as a whole. It will useful to consider how the concepts of training need and ITN have evolved over recent decades.
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Implementing level needs arise where the main problem is the gap between desired and actual performance. In other words, this is where people need to learn how to do the job well as defined by current standards. It is about learning to satisfy basic requirements and needs, in order to bring performance up to standard and maintain in there. Level 2 Obviously, level 1 need is, in a way, about improving individual or group performance that is currently lagging behind. However, when we refer to needs at level 2, we are talking about improving the performance of everybody Of the organization as a whole by raising current standards. This is where continuous improvement comes in Where we look at what we as an organization are doing and make systematic, organization-wide improvements so as to do it better, more efficiently and economically. Level 3 This represents a still further level of improvement making a step-change rather than one that is continuous or incremental. This can be done only by a through review of all our processes and of how they are interrelated, based on a review of our purpose why we do what we do. What are we trying to achieve? It must be stressed that these level are additive, i.e. To make successful to improvements we need to learn at level and then implement (level) the improvements.
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To be successful in innovation we need to learn at level and than implement (level) the new methods and continuously improve (level) than.
I3 Innovating
I1 Implementing
Fig.1 The additive nature of the three level of performance I1 : Implementing Adhering (1) learning to carry out basic tasks correctly. This is done by sticking closely to the rules laid down for doing the job and following precisely the set procedures. Adapting (2) when we may need to bend the rules slightly and make adjustment to procedures in order to make things work better. There may be minor changes in work circumstances as the job is being carried out. Relating (3) involves learning to understanding why things have been set up the way they have and why procedures work as they do as well as appreciating what needs to be done. Adhering, adapting and relating are the focused of most basic instruction and training, whether designed for newcomers to the work or to get people up to scratch if their individual performance has failed to match the standard required, or if for some other reason they are lagging behind.
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I2 : Improving For Improving performance, where our aim is to do things better, different types of learning are needed. This level requires (1), (2), (2) an ability to act more independently, to take initiatives and to make your own meaning and sense out of what is going on. So we are concerned with the following modes. Experiencing (4), i.e. being able to reflect on experiences and make our own meaning from them. Experimenting (5), i.e. learning to design and carry out systematic processes, in the form of experiments, in order consciously to discover more about the job and the work, normally in the terms of particular target areas deemed in need of improving. If people are encouraged to learn in these way (i.e. (4), (5)) considerable improvements can be made and performance enhanced.
I3 : Innovating
Performance at this level requires two sets of learning in addition to modes 1 to 5. here we are concerned with doing new and better things, and therefore learning has to concentrate on a more sophisticated and complex set of factors. Connecting (6), i.e. making connection between things, events, and people, and allowing integration and synergy to be achieved. We thus learn to work better with others, and particularly with people from different disciplines, who may have different perspectives and assumption, all of which need accommodating. Dedicating (7), where we learn to work out of a sense of purpose why we are doing something, and why we are doing something, and why we are doing it at a certain time and in a particular way. This should mean that we develop a clear sense of what
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is in it not just for ourselves, but for our colleagues, the organization as a whole, and the wider community.
Organizational needs
These concern the performance of the organisation as a whole. Information about this overall performance may identify areas of need either for training or other interventions. I1: implementing level Here ITN is about finding out whether the organisation is meeting its current performance standards and objectives, and, if not, exploring ways in which training or learning might help it to do so. I2: improving level Organisational needs arise at this level we want not just to meet current objectives but, for various reasons, to raise their level. I3 : innovating level These needs occur when the organisation decides that it has to adopt a major new strategy, create a new product or service, undergo a large-scale change programme, or develop significant new relationships, such as joining with others to form new partnerships. The reason that so many major change programmes fail (over 75 per cent, according to various research studies) is that they do not recognise the need to take a holistic view of all
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the systems - technical, human, financial, and marketing - and they do not involve a wide range of stakeholders in designing and implementing the change. Group needs These concern the performance of a particular group, which may be a team, department, function, sub-unit, or so on. Information about this group s performance may identify areas of need - which, again, may be for training or other interventions. I1: implementing level In this case ITN is about finding out how efficiently a particular team or group goes about its business and meets its current objectives. I2: improving level This level is where many continuous improvement projects are to be found, because these are usually carried out by teams. The team is able to identify improvement areas and also works together effectively to carry out many process and systems improvements. I3 : innovating level By working effectively with other teams across boundaries, major changes can be brought about, better relationships and communications be established, and new ways of working together be formed. Individual needs These concern the performance of one or more individuals (as individuals, rather than as members of a group). Again this information may identify specific needs. I1: Implementing level Here ITN is about finding out to what extent individuals need to learn or be trained to bring their current performance up to the required level
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as a result of changes in methods and processes that call for new competencies and skills. I2: Improving level Here ITN is about looking at the extent to which individuals need to learn or be trained in systematic, continuous improvement skills and how to take initiatives. I3 : Innovating level Finally, this is where we find out whether individuals need to learn how to think holistically, work across boundaries, examine their assumptions, or work with people from different backgrounds and with different perspectives. In Table 1 individual, group, and organisational learning needs are brought together at each of the three levels of performance, showing the wide range of what we may need to consider when carrying out a thorough training-needs analysis.
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2. Temporary worker A worker get the permanent job after the good and consistent performance in the company, these people are well experienced in their relative jobs. Temporary worker is a layman. They dont know any thing about the work, so these types of people require training. When a new person joins the company, he got the training about the safety and maintenance. For getting these training he is send in technical training cell (TTC). In TTC he has to go some basic knowledge and instruction, which is given by the just senior boss. That person is called line in charge. During the training a person gets the job. He is watched by the line in charge. At any point the line in charged found any fault in the work, the line in charge instructed at that time, so that the worker does the job in a proper way and come out with zero-defect product. There are several types of operations in the production, Ink filling Stopper Point tipping Capping Packing
After the TTC training employees are divided among various teams and send to the different operations, on the different operations. A line-in charge is there, who will watch each and every steps during the work. If any fault in the work is found, he takes that serious and instructs to remove the fault immediately.
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After some experience the worker is transferred from one operation to another operation area. Where same procedure is performed. He works and if get any confusion regarding the job, he may ask the line in charge or if line in charge see any fault during the operation, he educates the worker to do the job better. This process is repeated on each and every operation. This is how each and every employee is familiarized to the job . The main advantage of this job rotation is, if any worker does not come on the particular day, that place can be filled by any other worker and the works progress without any interruption. After job rotation and getting experienced the entire worker divided into three groups, Highly efficient Efficient Adequate If a person can handle all the machines related to any particular job. That worker is called highly efficient worker. After getting training 40% out of them became as highly efficient worker. These workers are very efficient and can handle any situation during the work. He can work on any machine at any time without any problem. These people can take decision at the critical point of time. So that these type of worker are called highly efficient worker. After highly efficient the second category is called efficient. In this category those type of person are master in their job. He is master in one job. In this category 50% worker comes. These types of people are well known people in their particular job. They are not able to handle the different machines. They feel problem in some job. After that the third category comes, that is called adequate. This type is not beneficial for the company. So that they are not acceptable. They have less knowledge and not will to work.
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Highly efficient person is well-known about their job. He can handle any situation. So that this type of people doesnt require training. Efficient people are master of just on job. So that they need training to be highly efficient worker. Company is giving training to the efficient worker. For them there are three types of training; Counseling Give the opportunity to work with highly efficient worker. Give the expert knowledge about the work. In counseling the instructor or line in charge counsel the worker. A line in charge tries to motivate the worker to do their job in proper way. This is a verbal communication. With the help of words a senior person tries to make them as effective as highly efficient worker. The second option provide them opportunity to work with highly efficient people helps those people to learn. During the work he can watch how the highly efficient people work? How can they handle the situation? They got the idea about the problem, which may be arising during the work. They also get the idea about dealing those types of problems. This way an efficient worker is developed to be highly efficient worker. Before start working every worker should get the knowledge about the job profile. Without proper knowledge no one can perform better. There must be some defective in the product due to less knowledge about the production process. So specific knowledge is essential for zero-defect product. This is the duty of management to educate them and provide full knowledge about the production process and quality control. For adequate people company has some other way for giving them training. The work pressure is the best way for make them work. Under this the adequate person is send to work between two highly efficient workers. Highly efficient people can work faster than adequate
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person. So from both sides he faces the pressure for work faster and effectively. This way an adequate worker can be the efficient and highly efficient worker for company. In any company some factor effect the training: Strategies changes Technical changes Matter of cost saving If the top management of the company want to change their strategies. Here company wants trained people for work. So firstly company looked for the experienced people, but it is very difficult to get trained people. So they hired semi- skilled people and after joining them they give them training. So that this can work effectively and according to the requirement of the company. If company wants some technical change in product, they also require trained people for work. Technical change requires more technical people. If company wants to retain the same people who are working form last some times then company has to give them training. After getting training a worker can adjust in any environment and work effectively. Todays era is the cost cutting era. In the intensive competition cost of the product is very important. We cant survive in the market with high cost. So we need to cut the cost of the product. For cutting the cost we need more trained worker who can work faster and quickly. So that the production time can be reduced. At lastly we can get the low price product. So that in every area we need trained people. For getting trained people we have to make them trained by giving training.
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METHODOLOGY OF TRAINING
There is various methodology of training. No single technique is always best. The best method depends on Cost effectiveness Desired program content Learning principles Appropriateness of the facilities Trainee preferences and capabilities Trainer preferences and capabilities There is a range of teaching methods available to trainer. The choice of a method is a matter of experience and competence of the instructor and his judgment of how much and what a particular group of trainees would learn from using one method or another.
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It also depends on the time and the availability of resources and infrastructural facilities.
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Types of training Job instruction training Job rotation Apprenticeships Coaching Vestibule training
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Supervisory training:
Supervisory training needs reveal utmost divergence in view of divergent duties of supervisors. Employee attitude surveys help in identifying area of supervisory training. Likewise, supervisors themselves may be requested to indicate the areas where they need training. Frequently, these surveys indicate that supervisors need training in human relations, production control, company policies and how to instruct. Supervisory courses consist of job methods training (JMT) and job relations training (JRT). The JMT helps the supervisors to improve methods in their departments, while the JRT helps them in handling human relations problems in their departments.
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Coaching Vestibule training Job instruction training: Job instruction training (JIT) is received directly on the job and so it is called on the job training it is used primarily to teach workers how to do their current jobs. The worker learns to master the operation involved on the actual job situation under the supervision of his immediate boss who has to carry the primary burden of conducting the training. Usually no special equipment or space is needed, since now employees are trained at the actual job location.
Advantages:
Easy organized Realistic Stimulates high motivation Speeds up workers adjustment
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Less costly
Disadvantages:
The disadvantage of this method is that the assigned instructor may be a poor teacher. The worker may haste for immediate production, so the actual cost may increase.
JOB ROTATION:
Some trainers move a trainee from job to job. Each worker move normally is preceded by job instruction training. This is a method of training wherein workers rotate through a variety of jobs. Thereby providing them a wide exposure. Trainees are placed in different jobs in different parts of the organization for a specified period of time. They may spend several days or even years in different company locations. In this way they get an overall perspective of the organization. It is used with both blue-collar production workers and white collar managers and it has many organizational benefits. Job rotation creates flexibility, during manpower shortages, workers have the skills to step in and fill open slots. The method also provides new and different work on a systematic basis, giving employees a variety of experiences and challenges. Employees also increase their flexibility and marketability because they can perform a wide array of tasks. Limitation of job rotation: The major drawback of this, it is time consuming and expensive too.
Apprenticeship:
An apprentice is a worker who is learning a trade but who has not reached the state where he is competent to work without supervision. It is particularly common in the skilled trades. In organization a new worker is tutored by an established worker for a long period
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of time. An apprenticeship lasts from two to five years. Each apprentice is usually given a workbook consisting of reading materials, tests to be taken and practice problem to be solved. This training is used in such trades, crafts and technical fields in which proficiency can be acquired after a relatively long period of time in direct association with the work and under the direct supervision of experts. Training is intense, lengthy and usually on a one to one basis. Increasing national attention is being paid to workforce preparation in the United States. This stems from the growing realization that America's ability to occupy a leading competitive position in the emerging global economy hinges, to a large degree, on assuring that the nation's workforce is second to none. Today, unfortunately, this is not the case. Employers frequently report that significant numbers of young people and adults alike exhibit serious educational deficiencies and are ill-equipped to perform effectively in the workplace. As a consequence, leaders from industry, labor, education, and government are all grappling with how to design educational reforms and education/training strategies that will improve the skills of America's current and future workforce. In the spirit of this reform, one particular training strategy -- apprenticeship -- has captured the interest of many policy makers, educators, and others who are involved in the national reform movement. Its growing appeal comes as no surprise and, perhaps, is long overdue. Experience both in the U.S. and growing abroad has repeatedly demonstrated that apprenticeship is a highly effective strategy for preparing people for work. The bulk of apprenticeship programs offered in the U.S. and its territories are in the building trades and manufacturing industries, but there is significant potential to develop apprenticeship programs in a variety of other industries.
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The rush to embrace apprenticeship, however, is leading to efforts that could undermine the very pillars of its value. For example, in some instances, apprenticeship is being viewed as a generic concept -- one that can be loosely applied to a variety of learning situations. Likewise, others have coined such terms as "youth apprenticeship" to characterize various school-to-work transition programs. Such thinking, while understandable in an environment that begs for creativity and innovation, may be more harmful than helpful to the cause.
3.
Apprenticeship is a training strategy with requirements that are clearly delineated in Federal and State laws and regulations. The National Apprenticeship Act of 1937 (also known as the Fitzgerald Act) and numerous State laws provide the basis for the operation of formal apprenticeship training programs in the U.S.; regulations that
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implement these laws are in force today. These laws and regulations establish minimum requirements for protecting the welfare of the apprentice such as the length of training, the type and amount of related instruction, supervision of the apprentice, appropriate ratios of apprentices to journeypersons, apprentice selection and recruitment procedures, wage progression, safety, etc. 4. Apprenticeship is a training strategy that by virtue of a legal contract (indenture) leads to a Certificate of Completion and official journeyperson status. These credentials have explicit meaning, recognition and respect in the eyes of Federal and State governments and relevant industries. 5. Apprenticeship is a training strategy that involves tangible and generally sizable investment on the part of the employer or labor/management program sponsor. 6. Apprenticeship is a training strategy that pays wages to its participants at least during the on-the-job training phase of their apprenticeship and that increases these wages throughout the training program in accordance with a predefined wage progression scale. 7. Apprenticeship is a training strategy that involves a written agreement and an implicit social obligation between the program sponsor and the apprentice. The written agreement, which is signed by both the apprentice and the program sponsor and is ratified by government, details the roles and responsibilities of each party. The implicit social obligation gives employers or program sponsors the right to expect to employ the apprentice upon completion of training given the investment in training and gives the apprentice a reasonable right to expect such employment. Labor market conditions
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should guide the size of training programs to enable each party to maintain his or her side of the obligation.
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A Policy Recommendation
As the education and training system in this country undergoes its restructuring, how apprenticeship fits in must be considered. Some may argue that the definition of apprenticeship should be boarded to encompass some or all of the previously described alternative training strategies. Unfortunately, this could have the practical effect of seriously undermining a tried and true training strategy -- on that, ironically, exhibits all ten qualities that reformers are striving to achieve in new training designs. Of particular concern is the possibility that an expanded definition could significantly dilute the value and meaning
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attached to the apprenticeship credential. Today, an apprentice who earns a Certificate of Completion and attains journey worker status from a registered apprenticeship program knows that he or she has acquired industry-defined skills at industry-accepted standards of performance and can reasonably expect to be gainfully employed in his or her occupational area. If alternative training strategies (ones that do not fully conform to the essential components) are also permitted to call themselves "apprenticeship," the apprenticeship credential stands to become devalued. Such a step makes little sense at a time when other credentials -- such as high school diplomas -- have lost much of their meaning. Thus, we conclude that their term "apprenticeship" should be reserved only for those programs that adhere to the eight essential components described previously. Other strategies may seek to adopt designs that conform to all the essential components, in which case they may be called apprenticeship. But to call any other types of programs "apprenticeship" is to do a major disservice to the participants in such programs. Whether intentional or not, the participants may be misled into thinking that completion of these programs will allow them to reap the benefits accorded to graduates of true apprenticeship programs. Clearly, we are on the verge of a major revolution with respect to how America prepares its workforce. As a new national training system emerges in the coming years, considerable thought should be given to the role of true apprenticeship in that new system. One on hand, apprenticeship could be the locomotive that drives this training system. Under this scenario, apprenticeship programs would serve as the principal form of training for preparing the majority of the nation's workforce. Alternatively, apprenticeship may become one of several cars on a train that provides a variety of training options to existing and future workers. This choice requires further study and broader deliberation, but, whatever the
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outcome, the integrity of the term "apprenticeship" should not be jeopardized or compromised.
Coaching:
At management levels Coaching of immediate subordinates by their managers is common. A coach attempts to provide a model for the trainee to copy it tends to be less formal than an apprenticeship program. Coaching is almost always handled by the supervisor or manager. It is likely not to be as directive approaches such as nondirective counseling or sensitivity training. If the trainees shortcomings are emotional or personal. Coaching will be ineffective if relations between trainee and coach are ambiguous in that the trainee cannot trust the coach. Coaching thrives in a climate of confidence, a climate in which subordinates respect the integrity and capability of their superiors.
Vestibule training:
Vestibule training is a type of instruction often found in production work. A vestibule consists of training equipment that is set up a short distance from the actual production line. Trainees can practice in the vestibule without getting in the way or slowing down the production line. These special training areas are usually used for skilled and semiskilled jobs, particularly those involving technical equipment. Vestibule is small, so relatively few people can be trained at the same time. The method is good for promoting practice a learning principle involving the repetition of behavior.
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people with work experience are participating. This method involves one-way
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communication, which is not interaction of the audience. This method cant readily adopt itself to individual differences, which may arise farthest from reality.
Audio-visual techniques:
Audio-visual techniques covers an array of tainting techniques, such as films, slides and videotapes. It allows seeing while listening and is usually quite good at capturing their interests. These methods allow a trainers message to be uniformly given to numerous organizational locations at one time and to be reused as often a required.
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Role playing
Active participation rather than passive reception facilitate learnings. Role-playing believes in active participation. This is a training method often aimed at enhancing either human relations skills or sales techniques. Role-playing can be defined as an educational or therapeutic technique in which some problems involving human interaction, real or imaginary is presented and then spontaneously acted out. Participants suggest how the problem should be handled more effectively in the future. This acting out is followed by discussion and analysis to determine what happened and why and, if necessary, how the problem could be better handled in future. Role-playing is less tightly structured than acting, where performers have to say set lines on sue. Participants are assigned roles in the scenario to be enacted, so , in this way, it is a device that forces trainees to assume different identities. Usually participants exaggerate each others behavior. Ideally, they get to see themselves as others see them.
The typical Role Involves Three Phases The Warm Up : the objective of the warm-up is to get the trainees participate in a
constructive manner with minimum anxiety and maximum motivation. The trainers introduction to the session should be such that it would arouse interest of trainees.
The Enactment: before conducting the role-play-enactment, the trainer should carry out
the following:-
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(a) Read aloud generation information, (B) Those who have volunteered to role play are given briefing sheets and sent out of the room with the instruction not to communicate amongst themselves, (C) The instructor should clarify all the doubts that role player might have, (D) Role players take their positions facing the class, (E) To begin the role play, the trainer sets the scene by restating the identify of the roles being enacted and making a brief statement about what has just happened when the action began.
Case Study
By studying a case situation, trainees learn about real of hypothetical circumstances and the actions others take under those circumstances. Beside learning from the content of the case, a person can develop decision making skills. Case method is an excellent medium for developing analytical skills. Cases are usually organized around one or more problems or issues that are confronted by an organization. Cases can range from one page to over fifty pages. Feedback and repetition, are usually lacking. One inherent difficulty is personal bias. This method calls for skills with language. But many people are sent to case study courses primarily because they lack communication skills.
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When cases are meaningful an similar to work related situations, there is some transference. There also is the advantage of participation through discussion of the case. It improves participants skills in problem analysis, communication and particularly brings home to the participant that nothing is absolutely right or wrong in the field of human behavior. Survey results indicate that the case method is considered by training directors to be the best methods of developing problem solving skills.
Simulation
Simulation is an approach that replicates certain essential characteristics of the real world organization so that the trainees can react to it as if it were the real thing and then consequently transfer what has been learned to their job. Simulation training is based on a reproduction of some aspect of job reality. Simulation usually enhance cognitive skills, particularly decision making. A very popular training technique for higher level Jobs in which the employee must process large amounts of information. Simulations have many forms- some use expensive, technical equipment, while others are far less costly. Some simulations need only one participant, others may involve as many as 15-20 people working together as a team. Simulations are a broad based training techniques that can be adapted to suit a companys need. By using the equipment simulators, workers can practice new behaviors and operate certain complex equipments free of danger to themselves. Equipment simulators can range from simple mock-ups to computer based simulations of complete environments. Some of them are utilized to train a single individual and the others are used for team training. Programmed instruction is a training approach which makes the advantages of private tutoring available to large groups of students beings trained in new skills. Programmed
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instruction is one of the innovations in teaching technology developed in recent years. The methods involves an actual piece of equipment, usually called Teaching machine, of a specially constructed paper booklet. The participants are active in the training process. In fact they determine their own learning pace. What is to be learned involves many discrete pieces of material, and the participants get immediate feedback on whether they have learned each piece. The major advantage of programmed instruction is that is reduces the training time. The learning takes place at the students own pace. Participants get immediate feedback. The participants are active learners, there is constant exchange of information between themselves and the programme. Fast learners do not have to wait for slow ones to catch up. Administrative simplicity and increased productivity in training result in lower training cost per student. The biggest disadvantage of this method is the absence of a teacher. The book becomes the teacher. Hence it is absolutely essential that the trainee is highly motivated to continue learning. The material has to be broken down into a logical sequence, since there may be several correct ways to perform the task. This methods does not appear to improve training performance in terms of immediate learning of retention over a time compares with conventional methods.
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Trainees also react favorably to this method. The computer is capable of assessing the progress of the trainee and can also adapt to his/her need by virtue of its storage and memory capacities. This method offers advantages of standard presentation of materials to all trainees standard, structured practices, and instant, specific feed back. The major drawback to C. A. I. For most organizations probably is the initial expense.
Syndicate Method
Working in small group to achieve a particular purpose is described as a syndicate method. The essence of this method is that participants learn from each other and contribute their own experience to the fullest. The syndicate method is designed to provide the participant an environment that would help him to reflect critically on his own work and experience; to update his knowledge of new concepts and techniques with the help of other co-participants; to develop sound judgement through greater insight into human behavior. This method is suitable for training and development students, without any experience. The participants are divided into groups consisting of about eight to ten participants. These groups are called syndicates. Each syndicate functions as a team that can represent various functional as well as interest areas. The syndicates are given assignments which have to be finished and a report submitted by a specified date and time. By rotation each member of the syndicate becomes the leader for completing a specific task. Each assignment to a syndicate is given in the form of a Brief. This is a carefully prepared document by the faculty. Generally, each syndicate is required to submit a report which is circulated to other syndicates for critical evaluation. The advantages of this method is that it secures a very high level of involvement from the participants. Their own experience is the starting point in this method. It is a process
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of self business and development for participants. This method also gives the participant a practice in communicating with his colleagues and understanding them. If the syndicate is not structured properly, it should lead to a lot of wastage of time and cause frustration. In the absence of proper pressure on the participants by trainers or participants themselves, some participants might start dragging their feet. Differences of opinion or viewpoint may be ignored to avoid action.
Behavior Modeling
According to social learning theory, most human behavior is learned observationally through modeling. When social learning theory is applied in industrial training programmes, it is commonly referred to as behavior modeling. Used behavior modelling to improve the interpersonal and communication skills of supervisors in dealing with their employees. The topic was first introduction by the trainers after which a film was shown to the trainees which depicted a supervisor model effectively handing a situation, followed by a set of three to six learning parts that were shown in the film immediately before and after the model was presented. A group discussion is them held in which the effectiveness of the method is discussed. After this, the practice session starts in which one of the trainee assumes the role of an employee. And then, feedback from the training class is given on the effectiveness of each trainee in demonstrating the desired behavior. At the end of each training session, the trainees are given copies of the learning points and are asked to try and apply them to their jobs during the following week. It has been found that this programme has had desirable effects on learning, behavior and performance criteria. There creation of the behavior may be videotaped so that the trainer and the trainee can review and critique it. When watching the ideal behavior, the trainee also gets to see the negative consequences that befall someone who does not use it as recommended. By
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observing the positive and negative consequences, the employee receives vicarious reinforcement that encourages the correct behavior.
effectively uses group interaction to develop in the participants a degree of self awareness. The primary objectives of the method is to inculcate in the participants the discipline of observing others and on the basis of this, provide objective and constructive feedback and to learn about oneself, ones behavior and personality as seen through the eyes of others and consequently to overcome weaknesses and improve upon strengths. The aspects to which the fish bowl exercise can be put to effective use are; individual and group behaviour , content of communication, roles individuals paly in groups, intergroup conflicts, level of participation, dynamics of group problem solving and decision making and, inter personal relations. The exercise can involve up to 25 participants seated in two concentric circles( one inner, the outer).the inner circle is the target group, members of this group will either discuss a preselected topic or move towards completion of a group task. After the discussion by the members of the inner group, the outer group is asked to comment on the content and more importantly the dynamics and group process of the inner group members Participants must learn to provide feedback with clarity and precision. Feedback must never be critical or it loses its constructive nature. After one cycle of the exercise is completed the outer group will change palces with the inner group and become the target group , inner group member become observers and the exercise is repeated. There are several non-group methods involving an assessment of each individuals strengths and weaknesses.
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Counselling:
It helps the trainees to observe their weaknessed and involves measures to overcome them. It is related to periodic appraisals of ratings. Specifically counselling purports to help the subordinates to do a better job, provides a clear picture of how they are doing, build strong personal relationships and eliminate, of at least minimize anxiety.
Understudies System:
In this the trainees work directly with individuals whom they are likely to replace. However,it is disappointing as a training because of a likelihood of an imitation of weak as well as strong points of the seniors.
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SKILL TRAINING
Proper training can be as important as the equipment used and other characteristics of the job. The money annually paid for training by business and industry also demonstrates the importance of training. It has been estimated that American business firms spend more than $30 billion per year on training and development, with some estimates running as high as $100 billion Motorola, Inc. alone spends about $44 million annually on employee education. Another indication of the importance business and industrial firms attach to training is the estimate, made a few years ago, that some forty five thousand employees across the United States were assigned full-time to training and development activities. Since then the figures have no doubt grown. This broad definition of training includes both skills training, which is usually of a technical nature and has a short-term focus, and management and career development programs, which are aimed at educating employees above and beyond the immediate technical requirements of their jobs in order to increase the organizations present and future ability to attain its goals. Thus, management and career development tend to be more future oriented than skills training. The purpose of skills training is to bring the competencies of individuals up to desired standards for present or near-future assignments & develop new skills and knowledge to replace those that have become obsolete as a result of technological organizational changes. The seven major steps, as shown in figure are the following:1. 2. 3. Determining the need for skills training Translating skills needs into training objectives Formulating the budget
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4. 5. 6. 7.
Selecting trainees Choosing a training method Selecting and educating trainers Determining evaluation procedures
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5S TRAINING
What Is 5S? The five S stand for the five first letters of these Japanese words: Meaning Seiri Seiton Seiso Seiketsu Shitsuke Sort Set in Order Shine Standardization Sustain
Calling this principle 5S is a good way to remember its content. 5S is a set of techniques providing a standard approach to housekeeping within Lean Manufacturing. It is often promoted as being far more than simply housekeeping and some of the elements described below certainly move into broader areas. A cornerstone of 5S is that untidy, cluttered work areas are not productive. As well as the physical implications of junk getting in everybody's way and dirt compromising quality, people are happier in a clean and tidy environment and hence more inclined to work hard and with due care and attention. Naturally enough, the elements of 5S are all Japanese words beginning with the letter S. Since their adoption within Western implementations of JIT, or Lean Manufacturing, various anglicized versions of the terms have been adopted by different writers and educators.
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These are listed below against the individual elements and it can be seen that none are entirely satisfactory. There are some symptoms by which we are able to know that we require 5s training methodology. Space is crowded with parts and tools. Unneeded items are stacked between workers. Excess inventory on the floor. Excess items and machines make it difficult to improve process low. Equipment is dirty and a collection point for miscellaneous materials. Needed equipment such as tools is difficult to find.
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Put simply, we may identify a large area devoted to tools or gauges, some of which are needed regularly and some used infrequently. This brings all sorts of problems, including: Operators unable to find the item they need, being unable to see wood for trees. The time spent searching is a waste (or in Japanese lean-speak a muda) and if we only held the items needed regularly in a prominent position we would save time.
o
Quality issues when gauges are not calibrated on time because too many are held.
Safety issues when people fall over things. Lockers and racking cluttering the production area making it hard for people to move around or to see each other and communicate.
Some of the standard texts also talk about the elimination of excess materials and WIP. This is a complete restatement of all the JIT goals of releasing capital, reduced movement, shorter cycle times and so on. The question may be asked: should we then see inventory and WIP reduction as part of the implementation of the lean approach or as an element of 5S? The answer, as ever, is that keeping inventory and WIP to a minimum is simple best practice. Whether we view it as JIT, or lean, or 5S or assign any other term is quite frankly irrelevant.
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The major element of Seiri is simply a critical look at the area. Involving crossfunctional teams, or getting people to look at each other's areas, is an obvious first step. People tend to be blind to failings in their own area and a fresh pair of eyes can be useful. Another element of the standard approach is 'red tagging' where items are given a tag which says what the item is, which location it is in and when it was identified in this location. We then leave the area for a while and anybody using the item notes this. We go back some time later and can readily identify things that haven't moved, or been used.
Items which have not been used can then potentially be disposed of. As a first pass we should perhaps create a quarantine area before throwing items away, selling them or reworking them into something else. Other items may be deemed necessary but used infrequently and so an alternative location can be found. If the operator needs a particular tool only once or twice a month then a 20-yard walk is not a problem - especially if the space thus saved on the workbench helps to make the area more productive, or helps address quality issues. 2. Seiton (Set in Order) Seiton is the series of steps by which the optimum organisation identified in the first pillar are put into place. The standard translation is Orderliness but again some wish to keep the initial S and use Sort (yes, that is also one of the translations of Seiri), Set in order, Straighten and Standardisation.
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The sorting out process is essentially a continuation of that described in the Seiri phase. Removing items to be discarded or held in an alternative location will create space. This space will be visible and facilitate the alternative layout of the area. In some cases, of course, we are talking about what a fitter will have on his bench, or in racks alongside the bench. In other cases we may be considering where we should locate a piece of plant - for example we may relocate a coin press to enable items to be completed in one work area rather than requiring a significant movement down the shop. This is something which we also undertake when adopting cellular manufacturing. We then look at how we can restructure the work content so that certain operations can be carried out within the cycle of others - for example we may carry out a trimming operation on a steel component while the press which produced it is busy creating the next one. Again, is this a 5S initiative, or part of a kaizen programme, or something else? Again, who cares, as long as we get on and achieve an improvement in business performance? Standardization includes all the elements of setting out a consistent way of doing things. This includes standard manufacturing methodologies, standard equipment and tooling, component rationalisation, drawing standardisation, consistency in the documentation which accompanies work, design for manufacture (or concurrent engineering) and standardisation in the clerical processes which deliver work to the shop floor and track its progress.
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All of this could be said to be part of a basic Total Quality approach. The standard ways of doing things should include poka-yoke or error-proofing. Again it might be asked whether this is part of 5S or one aspect of a broader programme. 3. Seiso (Shine) Anglicised as Cleanliness but again the initial S can be retained in Shine, Sweeping. There is a more practical element in that if everything is clean it is immediately ready for use. We would not want a precision product to be adjusted by a spanner that is covered in grease which may get into some pneumatic or hydraulic fittings. We would not wish to compromise a PCB assembly by metallic dust picked up from an unclean work surface. Other issues are health and safety (people perhaps slipping in a puddle of oil, shavings blowing into people's eyes) and machine tools damaged by coolant contaminated by grease and dust. The task is to establish the maintenance of a clean environment as an ongoing, continuous programme. Some time should be set aside for cleaning each day, or each shift. (We may have cleaners who come in a sweep office floors, and even clean the floor in a production area, but they do not clean the production equipment. Even if they did, this would miss one of the opportunities available - an operator cleaning and lubricating his machine tool will spot worn or damaged components.) Cleaning then begins to impinge upon what we already know as preventive
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maintenance. Cleaning critical components of a piece of equipment is already one element of the activities carried out under the PM banner. The implementation of Seiso revolves around two main elements. The first is the assignment map which identifies who is responsible for which areas. The second is the schedule which says who does what at which times and on which days. Some of these happen before a shift begins, some during the shift and some at the end. Again, this is very reminiscent of what we do when adopting PM. The standard texts such as that of Hiroyuki Hirano then go on to talk about establishing the shine method for each item / area. This includes such elements as agreeing an inspection step at the beginning of each shift, establishing exactly how each activity within the programme is to be carried out. A key aspect is very much akin to set-up reduction (or SMED) in that we should be aiming as much as possible to internalise the activities - in other words, to minimise the downtime needed to keep the facilities clean. Finally the standard texts talk about preparation - making sure the equipment needed to clean is always available, always ready for use. The best parallel to this is, again, with set-up reduction, which itself is often compared to Grand Prix teams preparing to change tyres. As with many such topics, we are talking about here is to a large extent simply common sense. We do not wish to allocate 5 minutes for a bed to
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be swept on a piece of grinding equipment if the operator is going to spend 4 minutes finding his brush.
4. 5s Seiketsu (Standardization)
This is best described as Standardised cleanup, but other names adopted include Standardisation (not to be confused with the second pillar), Systematisation and Sanitation. Seiketsu can be the thought of as the means by which we maintain the first three pillars. There is, obviously, a danger in any improvement activity that once the focus is removed and another 'hot button' grabs management attention, things go back to the way they were before. Seiketsu is the set of techniques adopted to prevent this happening. Basically this involves setting a schedule by which all the elements are revisited on a regular basis - usually referred to as the '5S Job Cycle.' The first step in the cycle is a periodic review of the area, perhaps involving red tagging but certainly involving people from other areas of the business. This will identify where standards have slipped - for example where pieces of tooling or fixtures which are used infrequently are no longer being put in the remote location agreed at the outset and consequently a bench is now cluttered with the regular items buried under a pile of irregular. (In other words, the Seiri phase is undertaken periodically - usually monthly, perhaps quarterly.) The second step is to undertake Seiton activities as required - that is, as prompted by the first step.
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Finally within Seiketsu people from other areas visit and cast a critical eye over the state of the area.
Again, an external assessor may notice degradation that is not clear to the people who work in the area. Hirano talks of a checklist within Seiketsu whereby the external visitors mark the area on a number of key criteria defined at the outset of the programme. For example, are the storage areas still clearly defined? Does the tool rack still have clear outlines or profiles for each tool to be stored in it? Does the area meet the general standards of cleanliness?
5. Shitsuke (Sustain)
The final stage is that of Discipline. For those who wish to retain the use of initial S's in English this is often listed as Sustain or Self-discipline. There is a fundamental difference between Seiketsu and Shitsuke. The fourth pillar is the introduction of a formal, rigorous review programme to ensure that the benefits of the approach are maintained. The fifth pillar is more than this; it is not simply the mechanical means by which we continue to monitor and refine, it is the set of approaches we use to win hearts and minds, to make people want to keep applying best practice in shop organisation and housekeeping. In this sense, discipline is perhaps an unfortunate term as it implies people forced to do something, with consequent penalties if they do not. The way in which management achieves this establishment of ongoing commitment within the workforce depends, of course, on the culture already in place.
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As with the adoption of kaizen (continuous improvement) or quality circles we have to press the right buttons to stimulate people. If the business has a history of treating people like cattle, giving no credence to their suggestions and simply trying to improve performance by driving the workers ever harder, then enthusiasm for any sort of initiative aimed at building a better environment is going to be hard to generate. There are a number of elements to any ongoing improvement activity in any business. Which take pre-eminence in a particular organisation varies with the history and culture of that organisation. Suffice to say that key points are:
o
Communication. We need people to be aware of what we are trying to achieve, and why.
Education. They need to understand the concepts and the individual techniques.
Rewards and Recognition. People need to feel that their efforts are recognised. Whether the reward is a senior manager walking past and saying "that's very good, well done" or some form of award (financial gain, prize or formal presentation of a certificate) depends on the organisation.
Time. If we want people to spend five minutes every four hours removing swarf from the floor around their machine we have to make sure that we allow them this time. We cannot give this as an instruction yet at the same time push for more time spent achieving productivity targets.
Structure. We need to identify what is to be done, by whom, and ensure that schedules are updated and clearly visible.
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Implementing 5S
Would we want to launch 5S as a stand-alone project, as a complete entity? The elements of 5S are all valuable in their own right but they simply form part of the bigger picture of establishing best practice. They sit alongside the other elements of Lean Manufacturing, or Just in Time, or World Class and some of the elements in, for example, Seiton (standardisation) are in fact straight lifts from textbooks on other forms of improvement activity. There is nothing in any 5S material, for example, to give guidance on improving the clerical processes for generating production paperwork following receipt of a sales order! The answer, surely, is to understand 5S as we understand all aspects of other types of improvement and problem-solving activity and then to agree a change programme for our own business. This is not to say that we must not launch a project which we call "5S" - some businesses have more success if improvement initiatives are launched with a generic, well-publicized term as project name. Equally, this is not the best solution in other organizations. Again, the history and culture of the company or the specific plant have to be taken into account when this decision is taken.
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OBJECTIVE
The objective of the project is to study training and development in company. As we know that training is an important factor for growing because growth is lifeline for the company. The main motto of this project was to know, how company conducts training program. What are the basic requirements during this process? How does the company come to know that some body needs training? After providing them training analysis is required. Analysis makes the management aware of the workers or staffs whosoever had gone through the training. Development is the main objective of any training. If there is no any development, the objective of training is not achieved. So for achieving the objective, development is very much required. The way of analyzing of the training should be carefully developed. Because a good analysis reflects the true figure of the development of trainees. How the company analyses the training is a subject to be learnt. So the ultimate goal of this project is to study the way of providing training as well as the way of measure the development of trainees in Dabur India Ltd.
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ii.
iii.
Out of the 20 staffs only 8 underwent the IT related training program. 8 got the training in personality enhancement. And 14 got skill enhancement training. It exhibits that most of them had all the three training program, skill enhancement, personality development and IT related.
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35%
In the analysis of the training program, the next question was, when the study material should be provided either before the training or after. Out of 20, 15 trainees opt that study material should be given before the training. And just 5 want the study material to be provided after the training.
Before any training program should there be any test for the purpose of selection of the trainees. Regarding this out of 20, 10 trainees replies in the favour of the test and 10 were against any such test. There is a no difference between both the views. So it is difficult to
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choose any one. In my opinion, before selecting a trainee there must be a test conducted by the trainer. It will help him to identify better trainees.
20%
10%
55%
The competence of the training program well defined has been assessed on the basis of certain qualities.
5%
On the aspect of gaining of new ideas in the training program, most of them found that, they got new ideas. The no. of staffs that had this type of thought is 15. Out of 20, 15 trainees
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think that new ideas gaining through the program was average. Just one person thought that, he get poor idea in the training program.
Self Development
5%
5%
30% 45%
15%
Out of 20%, I thinks that training is poor, 6 thinks training is fair, for 3 training is average, for a training is good and for 1 training is outstanding.
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The entire training program should be relevant to the job of worker or staffs. In search of this idea in the training program, it was found that out of 20 trainees 10 thinks, that while training program what-ever they got was relevant the current job. Rest 10 thinks that the program is not related of current job. This will be very helpful in the future to perform their job in a better way.
15%
5% 25%
40% 20%
Outstanding
Efficient use of time in the training program is very much important for every worker or staff, because every one wants to use his/her time efficiently.
15%
20%
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Maintaining the interest of participants is essential for the success of any program. It was found that no one says that he didnt have any interest in the training program. Out of 20, 7 trainees say that in the program their interest was good. Rest 13 says that, their interest in training program was normal and they are benefited more.
Clarity:
15%
10% 55%
30%
In any program, clarity is an important factor, without it we cant assume the success of any such program. The clarity of materials and lectures are very important in making the program a successful event. 11, out of 20 trainees say that the program is very good on clarity. Rest 9 says that the training program was average. The training program has mainly been areas rated on three parameters. i. ii. iii. Skill Enhancement Personality Enhancement IT Related
All the trainees have rated the training program differently on the basis of all the three parameters.
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Skill Enhancement:
5%
15%
According to the development of skills out of 20 trainees 11 have experienced good and 14 have experienced average (poor, fair, excellent).
Personality Enhancement:
10%
5%
25%
60%
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On the basis of personality enhancement 12, out of 20 trainees rated this training program good and rest 13 rated this program average (poor, fair, excellent).
IT development:
20%
15%
45%
According to the development in Information technology related areas out of 20, 9 staffs rated this training program good and rest 14 rated average (poor, fair, excellent).
5%
15% Every month every three month Every six month once in a year 50%
30%
The experienced of the training program is so impressive that all the trainees very much interested in these types of programs. They want more of such types of training programs. So
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3, out of 24 trainees want this type of training in every month .On the other hand 10 trainees want such program once in every three month. 6 out of them want to hold such types of program twice in a year. Rest of them wants to hold this once a year. In my opinion it should be twice a year.
65%
The duration of the training program is a big question for the management. All trainees who had attended the training program have different thoughts about that. 2 out of 20 trainees want the duration of these programs to be 8 hours. 13 of them want 6 hours and 2 want the duration to be 4 hours.
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Skill Enhancement
Personality Development
Total 45 workers have gone through these training programs. 2 out of them got the skill Skill
Enhancement & enhancement training, 4 got personality development, and 6 got skill enhancement & IT Related
personality development program. Out of 45 workers 8 got skill enhancement & IT related training, 11 got personality development & IT related training and rest 14 got all three, skill enhancement, personality development & IT related training.
To read the development after applying development programs questions are asked to the workers. Responding to the questions 16 out of 45 workers say that they go to improvement after the training program, 15 told that they didnt get any improvement and rest 14 are not able to say any thing.
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In any training program the material plays an important role. So it should be provided. But the question is that, "when should be the materials be given, before the training or after the training. In the responses of such Question, 30 out of 45 workers say that materials should be given before the training and 15 says that it should be given after the training.
A good trainee is essential for the successful completion of any training program. A good trainee can be selected by the test. So a test is required for selecting appropriate trainees. Responding this 27 out of 45 workers tell that they dont want to go through any test and rest 18 want to go through such test process.
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The evolution of any program is very much require for the future. It can be done by asking the trainees.
Skill Enhancement:
Responding to skill enhancement programs, 11 out of 45 workers say that the training program was good, 20 say that it ways very good and rest 14 trainees opine that training program was very helpful to enhance their skills and perform their job in batter manner.
Personality Enhancement:
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Responding to the personality development questions there are different views of the trainees, 6 out of 45 workers say that the program was good, 18 say that it was very good and 21 workers say that program was excellent.
IT related:
Responding to the IT related development questions trainees are very much conscious about their improvement. 10 out of 45 have good experienced regarding IT development, 13 say that program was very good and rest 22 have excellent experienced regarding IT in the training program.
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The duration is an important factor for the successful completion of any program. It should be according the requirement of the trainees. 2 out of 45 trainees say that duration should be 4 hours, 6 say that duration can be 8 hours. 10 out of them want 16 hours and rest 27 wants 20 hours for the training program.
Due to the changes in business the frequency of these types of training program should be higher. It should be according to the convenience of trainees. 10 out of 45 want this program should be conducted every month, 8 want after every three months but 20 thinks that the gap between two programs should be exceed 6 months. Rest 16 wants the frequency of these programs to be once in a year.
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the training process the efficient use of time should be made as time is the most important factor in any job. The frequency of training program is according to the requirement and convenience of the trainees as well as the management. Workers require more training so they need one in every six month. Staffs required less training in the compression of workers, so they required at least on training program every year. The duration of any event is the most important, which maker any program successful or fail. It should be according to the needs of the trainees of participants. In my opinion the sduration of the training would be 16 hours.
LIMITATIONS
Training is a costly affair for the management. It needs a handsome amount and long time. So management has to play safe game for the benefits of the company as well as the workers. One wrong decision may enforce the company to fall into deep troubles. So selecting the weak areas of staffs and workers should be done very carefully. For that the management should be conduct a test. For providing an effective training, company requires a knowledgeable trainer. Selecting a particular trainer is again a difficult job. Trainer demands handsome money. Training needs time and cost both. To conclude, it is very clear that training should be provided but not at the loss of the company. It is very costly and time taking affair. But it is most important for the development of the company. So management cant avoid it at any cost.
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CHAPTER - 6 ANNEXURE
TRAINING & DEVELOPMENT
(QUESTIONNAIRE)
1.
What types of training have you gone through? (i) Skill Enhancement (ii) Personality Enhancement (iii) IT Related (i) (ii) (iii) (i & ii)
(i & iii)
2.
Please indicate when should the study material be given to the trainees? Before the training After the training
3.
Before started training programme should you go through any test? Yes No
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4.
Program 1. practical values 2. New ideas gain 3. help full to self development 4. Relevance to your job 5. Efficient use of time 6. Maintaining your interest 7. Clarity
Poor
Fair
Average
Good
Out standing
5.
Rate these training programme according to your development. Poor Fair Good Excellent
In your opinion what should be the frequency of the training programme in your company. Once in a month Once in 6 months Once in 3 Months Once in 12 Months
7.
In your opinion what should be the duration of this training programme? 8 Hours 16 Hours 20 Hours
4 Hours
8.
Would you like to suggest some thing for the training programme? _____________________________________________________
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Date :
Signature
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CHAPTER - 7
BIBLIOGRAPHY
(1955). (1955).
Casio W.F. Managing Human Resource Mc Graw Hill book company, New York
Maslow Motivaiton & Personality Harper & Row, New York (1954).
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