The Papermaking Track at TAPPI's PaperCon 2012 event in New Orleans, La., USA, April 22 -25, features a very special paper industry success story—the company-wide transformation of Longview Fibre Paper and Packaging, Longview, Wash. Focused on the key role that operations training is playing in rebuilding Longview Fibre into a high performance company and an attractive investment for its owners, Bruce Warrick, operations training manager (photo on right), will detail how the mill has completely overhauled operator training from a highly informal, hit-or-miss process to a performance-based, results-driven program.
In the past, training for operations employees at Longview Fibre was done in a very informal manner, by supervisors and co-workers on the job. There were few standards or checklists, and mastery of skills was not a prerequisite for advancement—seniority was the only criteria. The trainer simply told the employee from memory what needed to be done, and the employee was expected to remember what was needed. There was no formal process to establish training timelines, track progress, or demonstrate competencies learned as a result of the training. Now all of that has changed.
The new operations training program launched in April 2010 includes consistent structure and delivery across all departments. The current curriculum consists of 86 unique training plans, each tied to a specific operating position. All employees in a particular job get the same training. The program now supports the company's core values of people, self-improvement, speed to action, and accountability, and is serving as a key lever in the company's effort to change its organizational culture from one of entitlement to one of empowerment and high performance. Operators are becoming more proactive and engaged in their jobs, resulting in improved efficiency and productivity.
Duncan and Peterson's presentation explains how the company selected the team that designed the new training program, and provides detailed insight into how it is structured. The entire program is delivered through a learning management system (LMS) and involves a blend of on-line learning, classroom training, and on-the-job training (OJT). Training plans include objectives, task lists for identification and location of equipment and systems, quizzes requiring a 100% score, references and resources such as manuals, work instructions (SOP), pictures, drawings, and purchased computer based learning modules. The OJT, or hands-on training, requires that the trainee be evaluated with a series of pre-determined, manager-scored field tests as a part of the qualification process. Electronic delivery through the LMS also improves basic computer skills as a side benefit for many of the mill's employees.
The training timeline includes completion of the training material online, field tests to demonstrate ability, progress checks to validate learning and provide teaching opportunities, and a scored qualification board review. Additionally, a standardized process was developed for scheduling and tracking of all trainees, progress checks and board reviews, including documentation and metrics. Each trainee is scheduled for training, receives orientation on training plan use, and is then scheduled for progress checks at set intervals.
Time to qualify depends on the position. Qualification is accomplished through panel interviews called qualification board reviews. A panel of managers asks pre-developed questions of the trainee, using a 0-5 scoring system. A minimum score of 90% is required for qualification. Emphasis is placed not just on how to do things, but on why. Post qualification expectations and follow-up with managers is required and a program for refresher opportunities is currently in the implementation phase.
The approach has proved to be so successful at the paper mill, that Longview Fibre will be rolling it out to the company's container plants this year.
More information about therPapermaking program keynote presentation as well as all program tracts and events at PaperCon 2012 is available online.
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