From entry level operator, to experienced process engineer… How does one get there? Training in the plastics industry is wildly important, arguably more so than in other industries, reason being (which I quickly learned) simple mechanical intuition does not do much for you in plastics. It is almost entirely its own craft.
This craft requires experience on the machine and exposure to how changes in a process can directly alter the part in your hand. Starting with the operator, small variations in cycle time or recognizing certain patterns as they relate to defects, is something that cannot be trained in a general manner, but is rather trained through hands-on experience and specified methods. It is learned through working side by side with the process engineer to help realize that one action of an operator could lead to something drastic happening with a part. For instance, a small distraction could lead to degrading material, or even seconds more of residence time can lead to a large run of defects, and understanding this in the plastics industry is crucial.
So, how will the operator learn that this action could have been a contributing factor to a defect at the end of the cycle? There must be a relationship between operator and engineer, where they are communicating and reaching agreements. Both perspectives can help each team member become better, and enable them to learn from the experience of running a job past its allowable scrap rate.
Training in plastics happens every day, through any new challenge to overcome. From the number of variables and possible contributors, to the daily experiences of men and women on the floor, it is an endless learning experience. When an instance of training happens in such a way, Wepco does a phenomenal job of communicating with other members of the team. We all know the importance of standardizing training, so whenever any member of the team makes a discovery, we allow for an opportunity to share. Our shifts convene regularly where we discuss quality concerns from a customer, and then how we as a team addressed them. This allows every member to buy into the process and become aware of the situation. This allows everyone on the floor to learn from this situation, carrying that knowledge around and possibly applying it weeks or months later when something similar is realized.
Ultimately, we have a structured training plan to use. It gets everyone started and exposes them to certain nomenclature used in the industry. But what this does most importantly is it exposes individuals to areas of potential to learn, then giving them the channels to share what they have learned. Wepco lives these values every day. “Never stop improving,” right? Living that value day in and day out, every day is training day.