CHENNAI, India — At Ford India, ongoing training for employees is critical to the growth and success of the business.
For around seven months of this year, the team at the Chennai plant has undergone the Global Team Leaders and Process Coach (GTLPC) training program to strengthen their knowledge of the Global Ford Production System (GFPS). The training was one of the largest training program of its kind and trained over 550 team leaders and process coaches.
Jointly organized by Ford India’s Lean Manufacturing Management (LMM) and Learning & Development (L&D) departments, the program had Operating Committee Members, Area Managers and Managers from various shop floors including HR, Finance and Safety departments training the Team Leaders and Process Coaches. The trainers themselves spent 712 man hours undergoing “Train the Trainer” sessions.
The Global FPS Strategy team has devised 12 modules for the training. The Process Coaches complete 55 hours of training spread over nine days while the Team Leaders have to attend 38.5 hours over six days — spread over 16 waves of training. Modules such as Ford as an Aligned and Capable Organisation, Operating Systems, Key Unifying Processes and leadership skills are part of the training.
As many as 46 trainers delivered the program, clocking 767 hours of training covering 116 days. This was carried out despite the production pressures following the launch of the EcoSport.
By the end of the program, 180 Process Coach and 376 Team Leaders had completed the training sessions, clocking 23,904 hours of training. As many as 95 percent of the targeted Team Leaders and Process Coaches from the Chennai Vehicle Assembly Plant and Chennai Engine Plant completed the program.
Handing over certificates to the trainers and participants, Ford India’s plant site manager, Tom Chackalackal said, “The Global Ford Production System is the most effective tool being given to manufacturing. We have to study and imbibe the learning’s in our everyday work so that we inculcate the best practices. It’s not easy to effect a cultural transformation overnight, but with training and gradual efforts we can achieve it.”
Adrian Price, director of Global FPS, Ford Motor Company, said, “I had the opportunity to spend time with the Chennai team earlier this month and see the impact of the Team Leader and Process Coach training that has been completed and saw the signed commitments to the process. It is clear that with the outstanding work that has been done the results are beginning to be realized across the plant. Well done team!”
Congratulating the team, dean of Manufacturing College, Ford Asia Pacific, Michael Popenas said, “The numbers are an impressive achievement constituting a solid foundation for continuous improvement and management commitment to the learning and development of our people."
Among others, Senthil Kumar and Balasundaram Radhakrishnan, plant managers of Vehicle Assembly and Engine Plant were present.
GTLPC Facilitators pose with Senthil Kumar, plant manager, Manufacturing, Ford India.