Case Study Reports

Harry Brown, Manufacturing Superintendent, The Johnson Company: "A year or so ago we had a lot of new people on the manufacturing floor. They were having trouble with in-process measurements. There was no consistency in measuring parts. Many of them didn't know how to use instruments. We often had errors of twenty-five thousandths when they were using a micrometer. They also couldn't read the prints correctly."

"Even our engineers needed some help converting a lot of old prints using our CAD system. We'd have disagreements on what the older drawings and symbols really meant. We put 20 people through the "Precision Measurement for Machinists" course. It worked just fine. A lot of the problems we had have been taken care of."

Gary McAllister, Training Coordinator, Hypertherm, Inc.: "We are very busy so it is hard to get people in for the training. We are expanding to 3 shifts. Some of the people had 2 years or less. Those that have begun the course are positive about it. Interestingly, I had a person with 20 years and another with 13 years at this plant that told me they learned some things from the first few lessons."

Bob Grove, President, Cosmos Enterprises: "We are relatively small, and we can't afford for people to make mistakes. We get involved with metric parts as well and I liked the ability to cover that area in the precision measurement course. Again, the simulations pay off here if it keeps them from making mistakes on our parts. I've been informed by QA that scrap has gone down significantly. It is basically nil."

Mike McGuire, Manufacturing Engineer, Dana Corporation: "We were moving from QS to the new TS 16949 quality standard. We needed to have training systems in place that met their requirements and had the documentation to prove the people got the training they needed. Most other training programs I looked at were kind of fluffy, but your course really gets to it. Our quality auditors realize that they must get 100% before the computer will let them progress to the next lesson, but they also know we are not looking at grades, we just want to make sure they have the information. We've completed about half the course and they are very positive about it. It couldn't be going any better."

Cheryl Lynch, HR Manager, Eaton Aerospace Machining: "Eaton - Charleston is implementing a Certified Operator program whereby every CNC operator and setup employee is required to complete the full MasterTask program, lathes, machining centers and precision measurement. After course completion they work with our quality department to ensure their parts pass complex aerospace quality. This program drives quality into the process; not quality driving the process."

"This certified operator program has been audited and recognized by our customers as a significant or best practice. While this was not our only intervention, we have generated a 72% reduction in scrap and rework over the last 2 years."

Matt Lofgren, Manufacturing Engineer, Kerr Group: "We manufacture bottle closures for the pharmaceutical industry. We had people in areas like the tool and die shop that needed help in measurement so I wanted ("Precision Measurement for Machinists") for my department. After we got it and the plant manager and HR director saw the materials, they decided to make it a plant wide project."

"I am thrilled to death with it. I like the geometric dimensioning and tolerancing job aids. That is a great tool for anyone working GD&T since we get a lot of argument about how a tolerance relates to the actual measurement technique. I had our tool maker and the tool and die coordinator go through it and now the quality assurance people. Our people are real impressed with it."

Russ Kemner, Quality Engineer, PoliHi Solidur: "We were getting quality problems that we traced down to measurement errors. We found we needed to improve skills company wide. I was impressed with the features of "Precision Measurement for Machinists" when I saw the sample. I had looked at a lot of materials, including some other online courses. I felt yours offered the most value for the price."

"We implemented the course at this plant and ran the management group through it. They liked it. The lead people were a little more resistant when we started on the first lesson. They thought they were wasting their time until they got into the interactive tests, then they developed an interest. It challenged them."

Scott Heath, Programmer, Precision Hydraulics Cylinders: "We started with the "Precision Measurement for Machinists" course. I went through the first few lessons myself and I was surprised by what I learned. We ran two classes a day, five days a week in order to train the 80 people we have across two shifts. At first some were asking why they had to go through the training, but once they got into it they really liked it, especially the simulations of the measurement procedures."

"After they completed just the first three lessons we began to see a reduction in tool damage. Our production manager has commented on the quality improvements he noticed as well. In fact, one of our customers recently told us that we had produced the highest quality rating ever on the products we shipped them."

Mark Cypranowski, Quality Manager, Tibor Machine: "We had hired an instructor to come in occasionally and teach Geometric Dimensioning and Tolerancing, but we didn't seem to get very far. Our operators walked out of class half asleep and with many questions unanswered."

"I like the 100% concept on the tests and the simulations of the measuring tasks. It really keeps their interest level up by keeping them involved and it is as realistic as it can be for something on a computer screen."

To become a certified operator now they must pass the course, yet it is relatively easy for them to do if they stay focused. It's not like a lot of training where they can get by on the cheap. But then, it needs to be because there is nothing cheap about their mistakes."