SECTION 1

Training Objectives Company History AMT Techniques Cell Safety PPE Job Description

TRAINING OBJECTIVES Reduce Inventory

1. 500% Improvement in Quality 2. Promote Creative Thinking 3. Increase Employee Knowledge and Growth 4. Improve Operator Problem Solving Skills 5. Improve Departmental Training Programs

ENKEI AMERICA, INC COMPANY NAME ADDRESS ESTABLISHED CAPITAL INVESTMENT SHARE HOLDERS

EMPLOYEES LAND AREA FACTORY AREA

Enkei America, Inc. 2900 West Inwoood Dr. Columbus, In. 47201 September 1985 (Production start April 1987) 21 Million US dollars 60% Enkei Corporation 20% Mc 20% Mic 630 155,515 m2 35,881 m2

CUSTOMERS Honda of America, Honda of Canada, Honda of Alabama, Honda Access of America General Motors Mitsubishi Motors Manufacturing of America Cami Automotive Subaru I suzu Automotive Southeast Toyota Distributors, Inc. Toyota Motor Corporation Nissan Motors Corporation U.S.A. Aftermarket HISTORY 1985 Sept-Established Company 1987 Feb-Start Trials March-GM QAV Approved April-First shipment to GM (3,600 Pieces) Oct-Capacity reaches 50,000 per month Feb-Plant Two start construction 1989 Dec-Plant Two Complete FebCapacity reaches 75,000 per month Jun-Start supplying to Japanese Companies in US. May-Capacity reaches 120,000 per month 1995 June-MAP Factory Finished Construction April-Received QS 9000 Certification Dec-Map capacity reaches 60,000 per month Total Enkei America Capacity reaches 180,000 Nov-MAP Facility added in Jacksonville, Florida 2001 Aug-Received QS 14001 Certification

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AMT Techniques

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The techniques used in the AMT ( Analytical Method of Training ) Program are designed so that the progress of the trainee can be measured. We break the entire job into several individual tasks. These tasks can then be taught in phases. You will learn more about this in the next few pages. The entire job is referred to as Single Cycle. Our goal is to teach you the proper pace, quality and methods so you can do your job with understanding and confidence. The first part of training is to teach you by telling you and having you follow along in a manual. We will quiz you to make sure that you are getting the general idea. We dont stop there. The next part is to show you. We will get the materials needed then have you watch and listen to how it is done. Next, we help you learn how to do it by talking you through doing it yourself. After that, we coach you by allowing you to do the job on your own while we oversee you. This is where the measuring of your ability comes in. These measurements are taking so that we can all see your progress. This way we can be sure that you are able to keep up with the majority of your job tasks. Can a person run 200 wheels, with quality, per day after 2 weeks of training and doing single-cycle? No. You need to have a chance to work up to this physically. You will have a trainer on-the-job after our single-cycle training to help you build up to the expected goals. This phase is referred to as Job Management. Getting your pace and organization such that you can run the entire job by yourself with the quality that is expected of and by our company.

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AMT Characteristics

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FEATURES OF AMT AMT..

Is Structured OJT Makes Full use of Present Staff Emphasizes Job Skills Training Including: Job Safety Job Quality Job Methods Job Output
Is a Success-Oriented System Rapidly Trains Employees in 1/3 the Time Promotes Measurement and Feedback Develops Consistency

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AMT Characteristics

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What is Training?
TRAINING Is the Transfer of Skill From one Person to Another

Is the Conversion of Knowledge into Performance

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AMT Characteristics

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What is Skill?
SKILL Is the Ability to Perform a Complete Job Cycle With the Safety, Pace and Quality of an Experienced, Expert Employee

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AMT Characteristics

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What is Performance? PERFORMANCE

Is The Achievement of Measurable Results

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AMT Characteristics

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Step-by-Step Approach to Learning a Job---The AMT System

Expected Production Level Full Day Longer Runs Short Runs Complete Job Parts of Job Job Exercises Basic Exercises Selection Usual Method

Job Management

Skill Development
The Ability to Complete One Wheel in Target (Single Cycle) Time

Stamina Development
The Ability to Produce at the Expected Rate for a Full Day

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AMT Characteristics

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SKILL BUILDING CYCLE

8 HOUR

4 HOUR

1 HOUR

SINGLE CYCLE S.C. Ability To Machine 1 Wheel

A-E

H-L

A-D

E-H

I-L

A+B A B C

C+D D E

E+F F G

G+H H I

I+J J K 1

K+L L2

Basic Exercises

Job Parts

Job Exercises

Skill Exercises

Single Cycle

Stamina Build

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AMT Characteristics

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TYPICAL RESULTS Of INEFFECTIVE TRAINING Extended Learning Times Incomplete Learning Variable Quality Variable Methods Higher Turnover

Higher Absenteeism

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AMT Techniques
Name Date

TOPIC

Job Day in Training

JOB PART EXERCISES

Job & Target
Section 2 Page 27 Wheel Parts Can Explain Common Terms Associated With Critical Design Elements of Wheels Section 2 Page 31 Casting Flash Removal Able to Recognize When it is Necessary to Remove Flashing and Also Demonstrate How to Remove

Results

Job & Target

Section 3 Page 39 Machines Can Explain Basic Machine Terminology

Results
1. 2. 3. 4. 5. _____ _____ _____ _____ _____

1. 2. 3. 4. 5.

_____ _____ _____ _____ _____

1. 2. 3. 4. 5.

_____ _____ _____ _____ _____

Section 3 Page 47 Stamper Set Up The Trainer Will Explain and Demonstrate how to Set-Up the Stamper. Trainee Will Demonstrate How to Set-Up Stamper

1. 2. 3. 4. 5.

_____ _____ _____ _____ _____

Section 3 Page 33 Process Can Explain Common Process Terms

1. 2. 3. 4. 5.

_____ _____ _____ _____ _____

Section 4 Page 58 Wheel Handling Can Explain Correct Wheel Handling Procedures for Different Elements of the job

1. 2. 3. 4. 5.

_____ _____ _____ _____ _____

Section 3 Page 36 Cell Specific Safety Can Explain Location of Machine Safety Features Including Energy Isolation Points, and Safety Interlocks. Also can Explain Personal Protective Equipment Requirements and Emergency Stop Procedures

1. 2. 3. 4. 5.

_____ _____ _____ _____ _____

Section 4 Page 68 Deburr Bolt Hole Area Can Deburr all Bolt Holes Within Target Time and With Acceptable Quality (No Burrs on Bolt Holes) Target ____________Sec. 5 Bolt Holes

1. 2. 3. 4. 5.

_____ _____ _____ _____ _____

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AMT Techniques

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JOB PART EXERCISES

Job & Target Section 4 Page 68 Deburr Window Area Can Deburr all Window Areas Within Target Time and With Acceptable Quality (No Burrs on Windows) Target ____________Sec. 5 Windows Section 4 Page 68 Deburr Valve Hole Area Can Deburr all Valve Holes Within Target Time and With Acceptable Quality (No Burrs on Valve Holes) Target ____________Sec. 5 Valve Holes Section 5 Page 73 Wheel Defect Recognition 1 2 3 The Trainer Will Coach the Trainee 4 During Machining to Make Sure 5 Trainee Recognizes and Disposes of Defective Wheels Correctly Results Job & Target Section 5 Page 101 Tagging Procedures Results

1 2 3 4 5

The Trainer Will Explain and Demonstrate how to Fill-Out Tags for Pallets, etc. Trainee Will Fill Out Pallet Tags Correctly

1 2 3 4 5

1 2 3 4 5

Section 5 Page 107 Related Forms ( Paperwork ) Can Explain How to Fill Out and Report on SPC Charts, Discrepant Wheel Report, Downtime, Dimensional Checks (Lathes and MC)

1 2 3 4 5

Section 5 Page 138 Tagging (Disposition of Wheels )

1 2 3 4 Can Explain Proper Disposition of 5 Good Wheels, Defective Wheels, QC Holds

Section 5 Page 96 100% Inspections The Trainer Will Explain and Demonstrate how to Make 100% Inspections on the Line. Trainees Will Demonstrate how to Measure 100% Dimensions Correctly

1 2 3 4 5

Section 6 Page 112 Tools and Gages Can Explain Name, Dimensional Gages Use

1 2 3 4 of 5

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AMT Techniques

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JOB PART EXERCISES

Job & Target Section 6 Page 114 Machining Center Dimensional Inspections The Trainer Will Explain and Demonstrate how to Make Machining Center Dimensional Inspections. Trainees Will Demonstrate how to Measure Dimensions Correctly Results Job & Target Section 6 Pages 153 SPC X Bar Chart Calculations Can Calculate the sum and Average of 5 Measurements (Positive and/or Negative with 100% Accuracy Results

1 2 3 4 5

1 2 3 4 5

Section 6 Page 124 Dimensional Inspections Trainer Will Coach the Trainee in the Proper Method, Timing and Accuracy of Making Dimensional Checks Trainee Will Correct Dimensional Inspections Techniques

1 2 3 4 5

Section 6 Page 153 SPC R Chart Calculation Can Calculate the Range of 5 Measurements, Positive and/or Negative With 100% Accuracy

1 2 3 4 5

Section 6 Page 149 SPC Trainer Will Coach the Trainee While SPC Procedures are Completed. Trainee Will Demonstrate Capability to Complete SPC Checks and Make any Off-Set Adjustments Necessary Section 6 Page 150 SPC Indicators of Out-of-Control Wheels Can Explain Trend, Run, Control Line Limits

1 2 3 4 5

Section 6 Page 154 SPC Chart Plotting Can Plot Points on SPC Chart From Results of Measuring Characteristics

1 2 3 4 5

1 2 3 4 5

Section 6 Page 166 Pilot Hole Adjustment Trainer Will Demonstrate and Explain Procedure for Making Pilot Hole Adjustment. Trainee Will Demonstrate and Explain the Procedure Show Steps Necessary to Make the Adjustment

1 2 3 4 5

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JOB PART EXERCISES

Job & Target Section 6 Page 166 Cap Hole Adjustment Trainer Will Demonstrate and Explain Procedure for Making Cap Hole Adjustment. Trainee Will Demonstrate and Explain the Procedure Show Steps Necessary to Make the Adjustment Results Job & Target Section 7 Page 177 Start-Up Procedures Trainer Will Explain and Demonstrate Procedures For Starting-Up Line After Weekend Shutdown. Trainee Will Demonstrate and Explain the Procedure and Why it is Necessary. Results

1 2 3 4 5

Section 7 Page 168 Rougher Change and Adjustment The Trainer Will Demonstrate and Explain the Correct Procedure for Changing and/or Adjusting a Rougher. Trainee Will Demonstrate the Procedure With Trainer Guidance.

1 2 3 4 5

Section 7 Page 177 Beginning Shift Procedures Trainer Will Demonstrate and Explain Start-up Procedures at the Beginning of Each Shift. Trainee Will Demonstrate and Explain the Procedure and Why it is Necessary

1 2 3 4 5

Section 7 Page 174 Chip Clean Out The Trainer Will Explain and Demonstrate Correct Chip Clean Out Procedures The Trainee Must Demonstrate How to Correctly and Safely Clean Out Chips Section 7 Page 186 Shut Down Procedures Trainer Will Explain and Demonstrate Procedures For Shutting Line Down at Last Shift Before Weekend. Trainee Will Demonstrate and Explain The Procedure and Why it is Necessary.

1 2 3 4 5

Section 7 Page 182 End-of-Shift Procedures Trainer Will Demonstrate and Explain End-of-Shift Procedures to Shut the Line Down. Trainee Will Demonstrate and Explain the Procedure and Why it is Necessary.

1 2 3 4 5

1 2 3 4 5

Section 7 Page 190 Controls

Can Identify and Explain Function of all Control Panels Robot, Teach Pendant, Lathe, MC, Orientator, Dip Tank, etc.

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AMT Techniques

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JOB PART EXERCISES

Job & Target Results Job & Target Section 7 Page 194 Job ManagementDimensional Checks The Trainer Will Explain How to Maximize Time When Making Dimensional Checks and Team Work Aspects of Shared Responsibilities. Results

Section 7 Page 190 Clearing Alarms

The Trainer Will Explain and Demonstrate how to Clear Alarms Associated With Open Doors. Servos, Orientators, Robots, etc. Trainee Will Explain and Demonstrate the Procedure With the Trainer.

1 2 3 4 5

1 2 3 4 5

Section 7 Page 194 Job Management- Loading Stocking The Trainer Will Demonstrate and Explain How to Load/Stock the Line For Optimum Job Management and Less Downtime The Trainee Will Loa/Stock the Line Accordingly

1 2 3 4 5

Section 7 Page 195 Job Management-Lunch and Break Relief Trainer Will Explain Team Work Aspect of Lunch and Break Relief And How to Maximize Productivity

1 2 3 4 5

Section 7 Page 194 Job Management-Shift Routines Trainer Will Explain Shift Routines That Will Maximize Productivity and Allow the Trainee to be in Control of the Line.

1 2 3 4 5

Section 7 Skill Cycle Trainee Will Demonstrate How to Complete One Wheel in Target Time (Loading, Deburring, Inspecting, Cleaning, Handling, Palletizing) Target: __________Seconds

1 2 3 4 5

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AMT Techniques

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JOB PART EXERCISES

Job & Target Section 7 STAMINA BUILDUP (On Line and Shift) Trainee Will Be Assigned a Job Management/ Stamina Buildup Trainer Who Will Guide the Trainee Through the Steps Necessary to Meet Departmental Shift Goals Based on Cycle Times, Cell, and Wheel Style. Section 7.1 HOUR RUNS Trainee Will Work Uninterrupted For One Hour to See How Many Wheels Can be Produced With Good Quality. 1 Hour Run Target____________ Wheels Results

1 2 3 4 5

1 2 3 4 5

Section 7.2 TWO HOUR RUNS Trainee Will Work Uninterrupted For Two Hours to See How Many Wheels Can be Produced With Good Quality. 2 Hour Run Target____________ Wheels

1 2 3 4 5

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Aside From Normal Plant Safety Rules, There are a Number of CELL SPECIFIC Safety Rules to be Practiced by Machining Operators. 1. Make Sure Long Hair is not Hanging Loose Around Conveyors, etc. as it Might Become Entangled in the Conveyor. 2. 3. 4. Do not Walk on Conveyors. Do not use Broken Wood Dividers or Pallets Watch for Coolant on Floor (Slip Hazard). Report Coolant Leaks to Your Supervisor.

5.
6. 7. 8. 9.

Watch out for Fork Trucks When Walking in Aisles and at the end of Cells.
Watch for Hoses Around Cell Areas (Trip Hazard) Look Out for Frayed Wiring on Fans, etc. Be Sure Fan Cords are Not Sitting in Water. When Hand-Loading Lathes, Watch out for Clamps. Wear Gloves When Handling Wheels and Deburring (Sharp Edges Can Cut).

10. Keep Your Work Area Clean and Free From Debris.
11. 12. 13. Know Where all Emergency Stops are Located and their Function. Do not Wear Loose or Baggy Clothing Around Cell Areas. Carefully Handle all Roughers and Sharp Machining Tools.

14. Stay Clear of OP1, OP2, and Machining Center Doors When it is Necessary to Enter the Cell. 15. 16. 17. Do Not Attempt to Catch a Dropped Wheel (Cut and Strain Hazard). When Loading Wheels, Make Sure Fingers are not Pinched Between Wheels. Be Sure to Wear all Personal Protective Equipment On Shop Floor at All Times. a. Slip Resistant Boots b. Eye Protection c. Gloves d. Ear Plugs When Entering Cell, be Sure to Remove Key (or Plug) to Disable Robot If More Than One Key (or Plug) is Missing, DO NOT START MACHINE UNTIL AREA IS CLEAR OF PERSONNEL. NO CLOSED CONTAINERS ANYWHERE ON SHOP FLOOR. 17

18. 19. 20.

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CELL SAFETY

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Personal Protective Equipment Requirements for Each Employee:

1. 2. 3. 4.

Eye Protection (Safety Glasses) Slip Protection (Slip Resistant Boots) Ear Protection (Ear Plugs) Hand Protection (Gloves)

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Job Description

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MACHINE OPERATOR EXPECTATIONS SUMMARY Handling wheels as they come from machining operations, de-burr, inspect according to audit requirements and stack on pallets. ESSENTIAL DUTIES AND RESPONSIBILITIES Include the following ( other duties may be assigned): Keep the line running at all times Handle wheels 100% visual inspection using inspection sheets De-burr all sharp edges Remove all chips from wheel Check plate and pin according to line and wheel model Check Cap and Pilot 100% Complete all dimensional audits and SPC checks on and by required times Make minor offsets to machines Lift wheels to skids Tag all skids correctly SUPERVISORY RESPONSIBILITIES None QUALIFICATIONS To perform this job successfully, an individual must be able to perform each essential duty satisfactorily. The requirements listed below are representative of the knowledge, skill, and/or ability required. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions. Trained to read basic process sheets and blueprints to determine machining to be done Trained to perform Statistical Process Control checks, tagging procedures, and de-burring Able to operate all production equipment within the department Able to complete all required documentation relating to quality and quantity of work. Able to clearly identify casting, machining, and paint defects. EDUCATION and/or EXPERIENCE High School Diploma or General Education Degree ( GED ); one to three months related experience and training. LANGUAGE SKILLS Read instruction sheets. Write numbers and instructions. Discuss production related issues with others.

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Job Description

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MATHEMATICAL SKILLS Ability to add, subtract, multiply, and divide into all units of measure, using whole numbers, common fractions, and decimals. Ability to compute rate, ratio, and percent and to draw and interpret graphs.

REASONING ABILITY Ability to apply common sense understanding to carry out instructions furnished in written, oral, or diagram form. Ability to deal with problems involving concrete variables in standardized situations.

CERTIFICATES, LICENSES, REGISTRATIONS None required. PHYSICAL DEMANDS The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions. While performing the duties of this job, the employee is regularly required to stand. The employee frequently is required to walk, use hands to finger, handle, or feel; and reach with hands and arms. The employee must frequently lift and/or move up to 50 pounds. Specific vision abilities required by this job include close vision, peripheral vision, and depth perception. WORK ENVIRONMENT The work environment characteristics described here are representative of those an employee encounters while performing the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions. While performing the duties of this job, the employee is regularly exposed to wet and/or humid conditions and moving mechanical parts. The noise level in the work environment is usually loud.

The above statement reflects the general details considered necessary to describe the principal functions of the job identified and shall not be construed as a detailed description of all of the work requirements that may be inherent in the job.

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