Metals Industry

Mill-Specific Training

GP designed and developed a complete training program for the operators and maintenance personnel on the hot strip mill (HSM) coilers and coil handling equipment. The program was designed to address training needs and coil quality issues both near and long-term.

The training program consists of mill-specific training manuals, procedures, and drawings utilized first for classroom instruction, then as input to training videos and computer-based-training modules (CBT). Additional mill-specific training modules are provided to maintenance personnel. A final session incorporates root cause failure analysis (RCFA), free-form problem solving, and instruction in a joint maintenance-production troubleshooting session.

The computer-based training (CBT) and videos are designed to make the positive impact of the training available on an on-line and individual basis. The CBT and video training is intended for use by new-hires, temporary employees, and vacation-relief workers from other mill positions. The CBT incorporates administrative and testing features. Employees can "test out" or take the entire module as initial or refresher training.

Useful job-aids, developed as part of the course development process, include tables explaining coiler controls and indications, coil quality troubleshooting charts, pileup response, and recovery procedures.

The training program was instrumental in effecting change and improvements in the coiler's—and ultimately the mill's—maintenance process. As a result of a programmatic approach to maintenance developed for the training course, an inspection program was initiated to help build backlog. GP's involvement grew from one of training to one of facilitating programmatic and cultural change in the mill.