Case Study Reports

David Evans, CNC Trainer, Emerson Electric: "I am not aware of a single crash by any of our new operators that went through the MasterTask course. Plus, our experienced CNC machinists improved their performance almost immediately. They learned to do things they weren't able to do before."

Robert Jackson, Quality Control Manager, Precise Machining and Manufacturing: "We've had a growth spurt. We received contracts with Boeing, Cessna, and Northrop Grumman. Many of our employees had learned their skills on-the-job. That process simply fails to give them all they need to know. In our initial group of personnel, we have produced a reduction in set up and down time. We liked the idea that they could practice on these simulations without tying up our production equipment or making full-time teachers out of our supervisors. Plus, if the simulations eliminate just one mistake by one operator, it pays for a lot of training."

Walter Voros, Manufacturing Manager, Teleflex Canada: "This is the most effective CNC training I've ever seen. We've put 8 of our more experienced operators through the program. They all are very supportive of it and recommended that all our operators go through it."

Chuck Henzy, President, Precision Machine Products: "On a scale of 1 to 10, the effectiveness of on-the-job training is a 1, where as this approach is a 9. We haven't had any tool damage or machine crashes for quite a while."

Gary Bomhoff, Boeing: "The quality improvements and efficiency gains gave us a 10% increase in productivity. Scrap and rework caused by operator error declined by 87% on the Fanuc controlled machines."

Bob Grove, Cosmos Enterprises: "We are relatively small, and we can't afford for people to make mistakes. I especially liked the ability to have people practice on the simulations of the CNC controls so we don't have them learning by trial and error at the machines. We were also pleased that the course produced the type of documentation we needed for ISO 9000 purposes."

Marty Maschino, Manufacturing Manager: "Scrap has definitely gone way down on our first-article inspection. We would have a number pieces scrapped before we got one through inspection. Now the first piece usually passes. We don't have as many collisions either. They understand the code much better and that eliminates those big mistakes. We do a lot of short runs of 100 parts or so. Setups are frequent. I think we've seen a reduction there as well even though we've only completed the first three courses."

Sue Savage, Bronson Precision Products: "We brought in a lot of unskilled people for the machining areas because we had a crush of orders. Some were existing operators that had minimal skills, others were housewives and restaurant cooks. We took anybody we could get at the time. The supervisors said it made a significant difference. The amount of information the employees gained was tremendous. Those that have gone through all of the lessons are now doing setups on their own. We take efficiency on every machine each day and on each shift. Excluding any downtime for maintenance or setup, the goal for the employees is 100% efficiency. We are currently at 89%."

Larry Deen, Haldex Hydraulic: "We have a bunch of Mori Seiki lathes with Fanuc 18i controls and old Okuma with a Fanuc 6 control. We had had 3 crashes where it cost $21,000 to fix the spindles. They were crashing tools and making gross mistakes before the training. All the people (trainees) seem very pleased with the online courses. We have seen a decline in the number of machine crashes. While we did other things as well, I am sure the training is a big part of it."

Frank Clulow, New Hampshire Community College: "We started out with the " Mastering CNC Machining Centers" course. I had 20 people in the first class, which was really too many, but we paid for the courseware with that class. The retraining of experienced CNC people has really revealed some of the problems with basic on-the-job techniques. After going through the first few lessons, one of my brightest people with 20 years in the industry told me that he never fully understood the difference between Absolute and Incremental coordinates before."

"Since everyone gets 100% eventually on the tests, I evaluate the students by looking at the amount of time they spend on them. It is more important to have the reinforcement the simulations and test questions provide. The tudents really like the tests because of the immediate feedback and interaction they receive just like the video games they all grew up with. Yet, nobody gets hurt and machines don't get damaged."

Dale Wailezer, Clark College, Vancouver, Washington: "It's a 2 year program for CNC machinists. I also have a lot of people from industry coming back in to advance their skills. Everyone is self-paced in our open-entry / open-exit format. We are open from 8 AM to 10 PM each day. Ninety percent of the work is done in the lab. I had one experienced person in their twenties take the "Mastering CNC Machining Centers" course that was able to complete all 25 lessons and tests within 2 quarters by working 8 hours a day. He is now employed at a local shop for $20.00 an hour. Most students average 4 hours a day for a year working in the course."

"Since we started your program we have had as many as 80 to 100 people in a semester. My current class has 6 more people in it now than we had planned just to handle the demand. I also have 8 people waiting for the classes for next quarter. We are interested in looking at your online courses to help reduce the need for them to come to the campus to acquire the material."

Jim Hemphill, Holmes Community College: "We had several students in our class that had gone to the Mazak and the Okuma factory schools. Both commented that our course was much more comprehensive and that they learned a great deal more."

Tom Longman, Instructor: "The course worked very well. We installed the CD-ROM based tests on laptop computers and left the instruction and tests at the local plant. They then came to our campus and completed their lab work."

"They completed the course without a lot of contact with me. They were able to work on their own."

Robert Harn, Mid-East Ohio Vocational School: "I've looked at a lot of materials over the years and nothing I've seen in the industry compares. Your courses are really state-of-the-art."

"These are high-school students so we only have a limited amount of time with them. We used another company's 14 lesson series of training videos in the past. They are good, but I feel your materials are more advanced, have better graphics, and offer more with the use of the CD-ROM simulations. During the first year, we were able to finish through course 4 (19 lessons) of the machining center (out of 5 courses totaling 25 lessons). I think we'll eliminate some of the other materials from the curriculum next year and we'll be able to get through all 5 of your courses. It's very comprehensive."

"I'm a big advocate of your materials and I have recommended them to the local community college and others in manufacturing."

Christopher Groden, Tulsa Technology Center: "We began using the "Mastering CNC Lathes" and "Mastering CNC Machining Centers" materials a few years ago and started using the "Precision Measurement for Machinists" course recently. We contract with local manufacturing facilities to perform the training for them."

"Many of the people we work with in the state funded "Train-the-Trainer" program have between 10 to 15 years as foreman and supervisors in CNC. They often tell us they learn a lot from from the materials. It has been effective for both beginners and advanced machinists."

"MasterTask is our favorite curriculum for teaching machining from start to finish. We have been promoting it on a large scale in the local area. It made the difference for us over the last few years when things got slow."

Sam Chabelle: "Mastertask CNC courses are really great! I have learned a lot. My supervisor tells me that I do my job like I have more than 30 years of CNC experience."

Jerry Holt, President, Fastenair Corp: "He has learned quite a bit from your online training. He has moved into the shop and is doing his own programing and is running three machines. He is also doing set ups by himself for the most part."

Jacob Libel, Wainwright Industries: "I was working across from these machines in the welding area and decided to try to learn CNC to get a job over there. I really learned a lot from your online courses. I am running 2 Mori Seiki machines and a Mazak running the Mazatrol language. Two other guys run these machines on other shifts. One has quite a bit of CNC experience and started 3 months before I did, but I am producing the same if not more. It helped a lot."

Fay Aubuchon, the HR manager at Wainwright Industries: "We were very impressed with him. Jacob was always a good worker but now is considered our top person."

Marty Hoppe, General Atomic: "I am on module 19 out of 60 but I've written a good amount of code already and some of the guys use my programs here in the lab, even though I haven't finished the course."

Andrew Bergstrom, William Russell Limited: "We needed him to be able to learn about programming on the Fanuc zero and ten series controls. I liked the fact that he could take the lessons from home as well as in the office. He mentioned that it helped him quite a bit and I've noticed that his programming skills have improved."