tool & die team member development systemcargroup.org/wp-content/uploads/2017/04/palen.pdf ·...
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Wally PalenAssistant General Manager
Toyota Motor Manufacturing Kentucky
Body Operations
Stamping SSR Leader
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1300+ ACRES
total
8.1 MILLIONsquare feet under roof
$7 BILLIONKY investment
as of CY2016
Toyota Motor Manufacturing Kentucky (TMMK)
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CAMRY+ HYBRID
America’s Best-Selling Car for 15 years in a row
AVALON
+ HYBRIDToyota’s Flagship Sedan
VENZA**Built out 2016
2nd Largest Stamping Operation in Toyota Globally
80% Self Supply to Body Shop
Parts Supply (Toyota + Suppliers)
30,000,000 Parts
2nd Largest Die Manufacturing Plant
Body Shell (Aluminum)
On-Site Die Engineering
Trial Parts @ TMMK Mfg Line
What we manufacture in Kentucky
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Toyota Kentucky Brings Home Platinum Plant
Quality Award in J.D. Power Initial Quality Study
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Die
Face
Die
Design
Casting
Machining
AssemblyTryout
Measuring
Production
Trial
Modifications
From part design to
production
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Prototype tooling
• Shorten die build leadtime
• Improve first panel quality
Cost Reduction
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• Quickest succession of new models in history of Toyota North America• Highest workload in 25 years for Die Manufacturing
2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021
Actual Production
Planned Production
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21%
25%
29% 29%32%
36%
41% 42% 42% 43%
0%
5%
10%
15%
20%
25%
30%
35%
40%
45%
50%
2017 2018 2019 2020 2021
5 Year Retirement Eligibility (Tool & Die) TL Eligibility
TM Eligibility
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393
63
0
50
100
150
200
250
300
350
400
450
Applicants New Hires
GAP ANALYSIS
Did not show up for hands-on assessment
Failed electrical component of the skilled assessment
Failed the Select Assessment for Manufacturing (SAM)
Not having enough die experience (only machining skills)
Week # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Candidate Search
Resume Review
Computer Assessment
Hands On Assessment
Department Interview
Background Check
Medical Review
Formal Offer
Start Date
17 Week Hiring Process
84%
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1) Modify assessment criteria to meet current market condition
2) Advance In-House Training Systems
3) Develop Tool & Die Apprentice Program with Kentucky Trade School
4) Develop a Pipeline of Students for the Tool & Die Apprentice Program
5) Reintroduce the Skilled Team Member Development System (1991)
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Modify Assessment Criteria
to meet current market condition
Eliminated the electrical requirement for Tool & Die
Recalibrated the Select Assessment for Manufacturing (SAM)
Testing criteria does not match today’s “talent skillset”
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Advance In-House Training Systems Created a dedicated
Tool & Die Training Center
Hire team members with
strong aptitude and train
welding / hand skills for
Tool & Die
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Develop Tool & Die Apprentice Program Partnered with Bluegrass Community and Technical College
Assisted with securing funding for a new campus
Assisted with procuring equipment for the Tool & Die Program
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18 months: 2 days / week of classroom training (BCTC)
3 days / week working in Toyota tool & die shop
+12 months: Continued development in Toyota tool & die shop
1800 hours of work experience after 30 months
30 months
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Cost:
$11,147 - $157 per credit hour (71 hours)
Kentucky Educational Endowment Credits (KEE’s) / FAFSA
Compensation:
$40,000 for first 18 months ($15 to $19 per hour)
$40,000 for 12 months ($19 to $22 per hour)
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Grow the program with a full time skilled team member through:
- Educational sessions at local high schools (1000 students)
- Educate students on tool & die skilled trades
- Educate students on minimum requirements
- ACT Scores (Math 19, English 18, and Reading 20)
- KEE’s (Kentucky Educational Endowment) funding
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- Educate counselors on tool & die skilled trades
- 60 mile radius, hosted counselors with luncheon and plant tour
- Partnered with retired school Superintendents for diversity mentoring
- Weekly mentoring with former Superintendents
- Monthly mentoring with Toyota AMT Coordinator
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AMT Maintenance Pipeline Results (Example)Advanced Maintenance Trainee
Reached out to 1000 students
11% applied (111)
65% met requirements (72)
Students interviewed by company sponsors
Toyota hired 100% of students that completed the program
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52
5
32
15
0
10
20
30
40
50
60
GAP thru 2021 Step 1 & 2 Step 3 & 4 Step 5
94 Applicants Required
Traditional HR Apprentice / High School
Prod TM-> Skilled TM