Currently, there are no formal training programs available that enable employees to

understand and control a flatline process. Even when a flatline is in the commissioning stage of a new installation, the “training” conducted by each of the suppliers is how to operate their specific equipment. There is no-one available that will train the employees how to successfully control the total process. There are many inter-related variables associated with an automated finishing process. In order to operate the line successfully the engineers, maintenance personnel, and line operators must be aware of all these process variables and how to control them. Generally the line runs  well during the first year of installation. During this period the new line gets much attention from management and the suppliers. The line is under warranty and usually technicians from the suppliers are readily available. After the first year your line employees are now on their own without specific process training. Many problems develop when maintenance and operators do not know the problem causing variable exists. As the line ages, turn-over is frequently high so the training problem is self-perpetuating. A new flatline 

is major capital investment with an expected production life of 20+ years. Untrained and unskilled personnel are the largest factor that causes high first pass rejects and un-planned downtime. 

 

Training seminars review each machine and other components in your process. We explain the job of each component and the variables that effect the performance of that component. We also explain the necessary in-process maintenance that may be required and how to do in-process testing to assure finish quality outcome without losing production hours. The clear understanding of process variables also prepares the operators to quickly trouble shoot a problem should one occur. Maintenance personnel will also understand how the machine is supposed to work when a mechanical problem arises. Please note that any corrective changes or suggestions to existing process are based on "best practices" observed over years of experience.

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We recommend that plant engineers, maintenance supervisors, and line supervisors attend these training seminars.