SANAND, India — The Sanand Vehicle Assembly Plant (SVAP) may still be under construction, but it’s already set to train new hires. Using a simulated factory, workers are able to learn assembly skills before they build real vehicles on the completed assembly line.
Gary Johnson, vice president, Manufacturing for Ford Asia Pacific, inaugurated the TCF Training Build area in November.
“As we are launching a green field site to build world-class quality products here at Sanand, it is vital to train assembly shop team members on basic skills prior to on-the-job training on actual vehicles,” said Kel Kearns, plant manager, SVAP.
The TCF Training Build area includes 14 skill development exercises each employee is required to complete prior to starting assembly shop experience. These exercises range from basic hand-eye coordination and through completing assembly tasks within the cycle time using actual power tools, electrical nut runners and line side error proofing devices. The exercises give production operators required skills, including working in various postures and underbody torque applications. Other simulation exercises include working on various types of wiring connectors, coolant hoses, brake connections and air conditioning connections.
“After completion of basic skill training in the skill development area, production team members are equipped with facility know-how, which makes for quicker and safer learning on the actual assembly line,” said Anil Patel, area manager, Final Assembly at SVAP.
QUALITY MONTH: SVAP celebrated “Quality Month” in November, highlighting its focus on and commitment to quality in every aspect of manufacturing.
Several events and initiatives were held during the month to convey to employees the importance of quality. As part of the initiative, Q badges were distributed and banners were hung displaying the concepts of “One Ford” and “Mission - 0/100 Mindset; Vision Statement – High Quality and Low Cost.” Mornings were dedicated to starting work with Quality Quotes and Quality Gurus.
Nearly 115 salaried and hourly employees at SVAP participated in special sessions every day, covering topics like learning and awareness about Ford’s Quality Operating System; plant-level quality metrics like R/1000, FTT, CPU, TGW and the purpose and uses of data collection; and analytical tools like control charts, Six Sigma and basic 7QC tools.
Employees also took part in competitions to create posters and slogans, as well as quizzes, with prizes awarded to the top five performers.
The first batch of trainees get trained at the training area.