What Managers

Need To Know
About Training Their
Production Workforce
A Guide For Plastics Companies That Are Serious
About Developing A Fully Skilled Workforce
The Challenge...
An open invitation to anyone who does not want to spend a dime on training and
believes that structured in-plant training is just a waste time.

Unlike some plastics trainers, I started

out on the production floor. I have
since owned a tool shop, sold and
rebuilt molding machines, and am
currently active in the industry as a
hands-on engineer and trainer.

I have worked in the plastics industry

and have seen first hand the gross
amount of money and resources
wasted because of poorly trained
production workers.

It has been over 20 years now since

I founded A. Routsis Associates and
I’m honored to say that our training
materials are used in over 1,800 companies in 31 different countries. This includes
61 learning centers and educational institutions that use our interactive training
programs as part of their standard training.

Challenge: I am so confident that our training system will save you money that I am
willing to outfit your company with an in-house training system at no cost to you. All
your company has to do in return is train your employees and share a percentage of
your savings with us.

To discuss the details of this offer and to get your

in-house training without spending a dime up front,
please call me at (978) 957-0700 today.
Andy Routsis, President
A. Routsis Associates, Inc.

www. t r a inint er a ct iv e. co m
What to expect from this report
This report was created to help educate decision makers of companies that are serious about
developing a fully skilled production workforce. We’ll cover just about everything that’s involved with
implementing an effective, structured, in-house training program.

The Importance of Plant Specific In-House Training

An experienced and efficient workforce is a company’s most valuable asset. While the majority of managers realize
2
that training is important, many don’t take the time to devise and execute a structured training initiative. You’ll also
find some tips for setting up your facility’s training initiative.

Exploring the Different Methods of Training Your Workforce

The only viable solution for achieving workforce competence is to establish a structured, plant specific In-House
4
training program that combines interactive training and advanced process simulation, which is reinforced by job
specific, on the floor training exercises. Also covered are the critical success factors for a successful training plan.

Get a Measurable Return on Your Training Investment

We’ll help you justify the cost associated with training in-house by pointing out the areas that provide immediate
6
payback. We list the areas in which you’ll see improvement. We’ll also provide you with a payback calculator to
validate your facility’s situation.

Plastics Industry Survey Reveals Importance of a Skilled

Production Workforce
9
A comprehensive industry-wide survey revealed many statistics and conclusions relevant to plastics manufacturing
facilities such as yours.

What Can Make or Break Your Training Initiative

With over twenty years of workforce training under our belt, we know what can make or break a company’s training
10
initiative.

Choosing the Right Training Provider 11

10 requirements that you should demand from any training provider.

Global Standards for Plastics Certification (GSPC)

We’re the only training provider that offers proven, recognized Global Certification for operators and technicians.
12
This comprehensive system is being used in dozens of countries across the world, and is quickly being accepted and
implemented here in the United States.

A Program Designed to Guarantee that Your Employees

Get Trained
14
Our Training Assurance Plan goes above and beyond the capabilities of other training providers. We’ll come to your
plant, help you devise a training plan for each of your employee levels and see to it that the plan is executed by
following up with quarterly reviews.

Manufacturing Industry Survey Reveals an Overwhelming

Lack of Skilled Employees
15
A 2005 survey of US manufacturing derived many surprising concerns. With the skills gap continuously increasing,
the need for developing a high-performance workforce is greater than ever.

14 of the Most Frequently Asked Questions

Here are some questions that we answer on a regular basis.
16

tel: (978) 957-0700 email: [email protected]

 Problems Facing Plastics Manufacturers
x over $250,000.00 of scrap produced annually (results of 2005 survey)
x mountains of regrind in inventory
x smashed and damaged molds
x hundreds of machine hours lost weekly from technicians troubleshooting unstable processes
x over two hours spent changing over and starting up each job

What is the root cause of all this loss and damage?

In a recent industry survey, 100% of the managers and executives polled stated that these problems are a direct result
of a poorly skilled workforce. Don’t let under-trained employees run your company into the ground.

The In-House Training Solution

Even the best equipment cannot compensate for bad processing or a poorly designed mold. The solution to the
problems listed above is to improve the skill level of your production personnel.
Since it’s not logical to send all your production personnel away for training, the only viable option for achieving
workforce competence is to establish a structured in-house training program.
By significantly improving the skill level of the workforce, companies have increased their productivity by at least 37%
within the first year.

The Importance of Training

A business grows and profits when its employees are constantly increasing their knowledge and experience. No one
can dispute that an experienced employee is a valuable asset to any company. But while most managers realize that
training is important, many don’t take the time to set up a training initiative and keep it going.
Successful businesses always provide extensive and continuous training for their employees. This attention to
education and training is one of the reasons these companies are where they are today. A business can only grow
when its employees are constantly improving their skill levels. Setting up an in-house training program takes some
work, but the dividends are well worth it.

Why Train?
Training is one of the hottest topics being discussed by managers throughout the plastics industry. To be competitive
in today’s lean global marketplace, companies must continue to produce quality parts with a minimal number of skilled
employees.
Technology is constantly changing in the plastics industry. Materials have changed drastically, new machine control
systems are being introduced, electric machines are becoming just as common as hydraulic machines, and processing
techniques are being altered to keep up with the trends.

Why Make a Commitment to Training?

Reason #1: To Stay Competitive
An in-house training program gives you the competitive edge in today’s fast-paced plastics industry. Having trained
employees who understand the concepts of the molding process can better adapt to new production runs and can
troubleshoot in a more logical and efficient manner. The bottom line is that your company will run smoother and will
have a reputation for consistently delivering quality parts.

Reason #2: Commitment to Your Employees

Today’s customers are sensitive to quality, economy and worker safety. Customers are impressed with a job delivered
on time and on budget, and from a safe plant.
Imagine being able to boast that all of your production workers have gone through a comprehensive in-house training
program and that your company has a system in place for continually improving the skills of its workers! Not only does
this boost confidence and security among your employees, but it also tells your customers that you’re committed to
raising the bar.

“A survey of 42 injection molders who have had process improvement training

programs, indicated that their per machine profit increased by more than $13,000.”
Plastics World (February, 1993) ç Imagine that was over 12 years ago!

2 www. t r a inint er a ct iv e. co m
 Training Tips for Your Facility
è Be Aware that You Are Training Adults
Adults often have firm ideas of how to go about learning a subject. Realize that people receive information in a variety
of ways, and only a percentage of the material presented will be learned. When training, retention is the key for
developing applicable skills.
Studies have shown that people learn best from a combination of training methods that can be repeated over and
over again if necessary. Some concepts may have to be repeated as many as seven times to be remembered. Reading
books, magazines, and industry manuals can be helpful, but it’s not realistic to use such forms as a primary source of
training. Retention rates are maximized when the information is presented in a multimedia format - utilizing audio,
video, and on-screen titling.

è Refer to Yourself as the Facilitator, Not the Instructor

Adults often bristle at the labels “teacher” and “instructor”. We have learned that the preferred term when training
adults is “facilitator”. This title infers that the facilitator is not lecturing or preaching, but is there to help the employee
teach him or herself or provide the necessary pathway.

è Your Key Employee May Not Be the Best Facilitator

You might start off your training program by making your most valuable employee the facilitator. However, this
could be a mistake. This is not necessarily the best way to go about setting up the program. We’ve learned that an
organized and personable individual is more than capable of being a successful facilitator and can always ask a more
knowledgeable person for information on an occasional basis when necessary.
A good facilitator never infers to a participant that he or she is
incompetent or ignorant, and never gets angry at a participant for
not understanding. A facilitator’s patience is just as important as a
grasp of the subject matter.
Participants sometimes want to leave a course of study before
they have finished. This often happens because the participant is
confused or lacks confidence. It is up to the facilitator to get the
participant back on track to finish the course.
When choosing your facilitator, look for someone with a natural
inclination to explain concepts and help others. Your employees will
respect such a person, and will be grateful that you have chosen such
a good facilitator. They will also learn better and faster, and will make
the training more enjoyable for all those involved. After all, your
employees want to do a good job.

è Training Room Setup

When setting up the training room, it’s important to understand
the effect that the room will have on participants. If the room is
professionally appointed, clean and quiet, participants will take
training seriously. If it’s dirty and cluttered with noisy people
wandering in and out, the training room will seem more like a break
room or cafeteria, and little or no training will take place.
To set up the training area, choose a room as far as possible from
the production area. There should be sufficient lighting, enough
chairs and tables for participants to be comfortable, and a small shelf
with texts, magazines, manuals and other materials for participant
reference. Remove everything from the room that does not pertain
directly to training. If this isn’t possible, move boxes or other clutter
to a corner of the room and cover it up so it doesn’t distract the
participants.
Make and uphold a few simple rules to distinguish the training area from other areas of the plant. For example, you
might insist that no food, drink or smoking be allowed in the training area, and that breaks be taken outside the
training room. Make a sign with the rules and post it on the door. This tells participants that the training room is for
training only, not for socializing or coffee breaks. The room should be a soft, light color, such as pastel blue or green.
Avoid dark colors since it will put people to sleep!

To learn more, visit www.traininteractive.com/newsletter

and sign up for our FREE eNewsletter

tel: (978) 957-0700 email: [email protected]

 Exploring the Different Methods of Training Your Workforce
Available Training Options
Training comes in many different forms – books, manuals, videos and DVDs, seminars, computer-based interactive
training, process simulation software, and plant specific on-the-job training. Ideally, every company would like to
provide on-the-job training performed by a knowledgeable, experienced leader with a knack for instruction. However,
the right person for the job is often too busy producing to take the time to extensively train new employees.
We have determined that an effective in-house training initiative requires a combination of training methods.
A. Routsis Associates was the first training provider in the industry to actually travel to a plant, discuss the problems
that need improvement, and help devise a structured training plan geared to a specific operation. The following
paragraphs give a brief description of each available training method.

è Printed Materials
Books, manuals, and industry publications are inexpensive, easy to obtain, and can be used over and over again.
However, asking an employee to read and retain a large body of written information is somewhat unrealistic. Most
people require interaction in order to learn effectively. Printed materials are essential forms of reference but do not
provide any measured results.

è Video Training
Training with videos or DVDs is visually interesting and is somewhat inexpensive, but still lacks interaction and the
ability to monitor progress, unless hand written tests are passed out and logged by a facilitator. Another drawback is
that a video is a linear presentation that can not be customized. Video presentations can be very lengthy, and studies
have shown that retention drops after more than three minutes of continuous video. It is for these reasons that video
or DVD training are not viable options when choosing the best training methods.

è Seminars
There are several variables associated with classroom training, guest lecturers and seminars. Will the workers be able
to understand and keep up with the instructor? How much will they retain if they “zone out” during the session? How
many times will they have to repeat the session to apply it on the job? What’s the ideal number of employees to train
at one time? Although the information provided in a classroom setting may be useful, it is almost impossible to track
its effectiveness and should not be used as the primary training source.

è Interactive Training
Interactive training is continually gaining popularity throughout every industry. A. Routsis Associates combines
3-D animation, digital video from actual production environments, on-screen titling, and professional narration
– guaranteed to captivate the end user. Each training course contains an average of fifty questions that tests a
participant’s knowledge before, during, and after the program is delivered. This type of training is available 24/7 and
employees can learn at their own pace, creating a comfortable environment.
Since all of our training programs are up-to-date and use ‘industry best’ practices, the information presented to your
employees is undoubtedly relevant. Furthermore, each of our courses can be easily customized to your specific needs.
Interactive training provides measurable results and is most effective when used in conjunction with plant-specific
exercises. This ensures that the knowledge gained during the interactive training can be demonstrated as learned
skills.

è Process Simulation Software

This virtual machine allows the user to experience a ‘real’ processing environment minus the costs involved with
interrupted production, machine time, and material waste. Participants are required to ‘produce’ an acceptable
product within given specifications – utilizing interactive process control parameters to identify and remedy product
faults. Troubleshooting abilities are measured and logged as a spreadsheet for the facilitator to analyze. Process
simulation software is an ideal transition between interactive training and the production floor – allowing you to isolate
part defects, improve cycle times, and test various processing methods.

è On-the-Job Training
Hands-on training is perceived as the best way to train any employee, but it is very costly. For this type of training to
be successful, it must be conducted by an experienced supervisor or manager. With that being said, if you pulled one
of your best workers off the production line to become an instructor every time a new employee was hired, you may
suffer some consequences.
On-the-job training can teach an employee about the visible workings of machines, but not the inner workings, and
some processes may be too fast to see well. This is another reason why we suggest a structured “blend” of training.
When implementing an in-house training program, specific on-the-job training should be combined with other training
methods in order to be effective and efficient.

4 www. t r a inint er a ct iv e. co m
 Critical Success Factors
With over 20 years of training experience in the plastics industry, A. Routsis Associates knows the 6 critical factors that
can make or break your company’s in-house training program.

Relevant: The information being presented must be Customizable: Curriculum must be tailored to meet
relevant to their job and your plant. A comprehensive the specific needs of your plant. Training media, such
in-house training plan incorporates all of the training as interactive training, can be easily customized to your
necessary to instill a good base of fundamental business at no additional cost.
knowledge. Skill Development: Too often, participants learn a wealth
Captivating: Training must be captivating in order to of theoretical information yet do not understand how
keep the participants’ attention. Everyone knows that in to apply it to the workplace. After being trained, your
order to learn, you must pay attention – yet companies workers need to develop skills so the knowledge can
often rely on boring lectures and literature to train. actually be used.
Interactive: Employees retain significantly more Progress Monitoring: Tracking the results proves the
information in an interactive environment. Research has effectiveness of the training. Facilitators need to use a
shown a 38% increase in retention when using interactive training method which makes it easy to track and monitor
training compared to other methods. each employee’s progress.

You Wouldn’t Sit Through A Boring Presentation,

So Why Should Your Workers?
Just as presentations need to be captivating – so does your in-house training. Many companies place
a large importance on multimedia tools for sales and business presentations, but none of these tools
are used to train their workforce.
A study performed by the Department of Defense revealed a “38% increase in retention” as a direct
result of using multimedia training (Ultimedia Digest, 1, 5-8, 1992). Despite profound advances in
technology over the past decade, outdated learning practices are still being employed in plants
across the world. Without the use of multimedia presentation, nearly half of your training efforts will
be wasted.

Interactive Training Is the Most Efficient Option

When compared to other training methods, computer-based interactive training can reduce learning time by up to fifty
percent. This significant reduction in learning time is a result of the flexibility associated with interactive training.
• The combination of visual presentation with audio explanation delivers information in an easy-to-comprehend
format and gives the user the ability to essentially rewind and replay any section that is not fully understood
• As the user trains, the program monitors how much time is being spent and can provide the facilitator with
detailed test results
• By providing immediate interaction and feedback when answering questions, the content covered is reinforced as
many times as necessary until the user displays a predetermined percentage of mastery
• Self-paced instruction allows each participant to progress comfortably
• All of our interactive training courses can be customized to meet your company’s specific needs

Why Off-Site Training, by Itself, Is Not a Viable Option

There are many drawbacks to training your workforce using off-site training providers.
• It is impossible to send your entire workforce away for training
• Most people cannot apply off-site training to their production workplace
• Off-site training tends to cram extensive amounts of information into marathon sessions of time – counteracting
most expert recommendations of 1-2 hours a week
• Sending multiple employees to off-site training is most often cost-prohibitive

Off-site training initiatives are most effective in the role of introducing new concepts and theories, such as process
monitoring to key employees. In practice, companies only send managers and supervisors out for off-site training,
isolating the information and thus affecting very few workers.

tel: (978) 957-0700 email: [email protected]

 Interactive training is the most cost effective method…
…when compared to other forms of in-house training;
especially when broken down to a ‘per-employee’ basis. The
cost of hiring on site experts and trainers can be a very costly
venture, which can increase exponentially as the trainer
returns over time. By taking your employees off the floor for
days at a time, costs can exceed five to ten thousand dollars
per employee in labor costs.
Using on-the-job training as the exclusive method to train
all your employees is the most costly option out there by
far, since it requires time off the job for both the trainer and
trainee. Over a period of time, it has been our experience
that the information passed on is limited to a need-to-know
basis, making it sparse and incomplete.
It is impossible for most workers to convey both the
fundamentals and concepts necessary to make educated and
confident decisions. After a couple years, this apprenticeship
Additional benefits to interactive training: process can cost tens of thousands of dollars in the wages
• Low cost per employee with each of each employee. When factoring in the cost of wasted
additional person trained material, machine usage, and possible equipment damage
• Training can occur during unexpected – the overall figure can be staggering.
downtime and off-shift hours
Our interactive training solutions will impact your production
• Trained employees work safer and more workforce within three months for costs as low as a few
confidently
hundred dollars per employee.
• A commitment to training creates
company loyalty, thus reducting turnover
• Information is more consistent

What Improvements Can You Expect From Training?

Let’s face it — an employee that can recognize and correct problems is far more valuable than someone with
only a surface understanding of his or her job. Thorough knowledge of plastics production can be gained
through years of experience, but this means it will take a significant amount of time for a new employee to
become a valuable asset to an operation.
Savings Per Machine on a Yearly Basis
A greater understanding of the job at hand
Injection Molding Machine Hourly Rate
can be achieved through structured training.
By utilizing training, your new employees % Cycle Time
$30 / hr $40 / hr $50 / hr $60 / hr
can become “experienced” much quicker. Improvement
The effort required to set up a structured
10% $18,000 $25,000 $31,000 $37,000
training program is paid back many times
over by reducing; cycle times, scrap rates, 15% $28,000 $37,000 $47,000 $56,000
mold damage, regrind, machine downtime,
rework of parts, and employee injuries. Any 20% $37,000 $50,000 $62,000 $75,000
manager can quickly assign a monetary
25% $46,000 $62,000 $78,000 $93,000
value to all of these areas.
30% $56,000 $75,000 $93,000 $112,000
As an example of just how important training
is in reducing and optimizing an injection 35% $65,000 $87,000 $109,000 $131,000
molding process, the chart on the right
This table represents the cost savings per machine when improving process efficiency through structured training.
illustrates savings on only one machine! The annual figures above are based on a 5 day/24 hour operation.

Visit www.traininteractive.com/cases
to read a number of ROI Case Studies

6 www. t r a inint er a ct iv e. co m
 Can My Company Competent Workers Provide
Immediate Payback Through:
Really Justify
Spending Money Lower scrap rates
Reduced mold damage
To Train Our Decreased machine downtime

Employees?
Improved troubleshooting time
Faster machine startup
At Routsis we are constantly asked “I know we need training, Fewer defects
but how do I justify it?”. There are many ways to justify the cost
and quantify the associated payback areas. Since poorly skilled Consistent part quality
employees are the root cause of most production losses, the
highest return on investment comes from these three categories: Highly repeatable processes
Scrap, Downtime, and Equipment/Mold Damage.
Shorter cycle times
In a recent industry survey we found that most companies lose over
a quarter of a million dollars annually just in scrap and reworked Less accidents
parts, yet are not willing to invest a fraction of this to remedy the
problem. As a result, the trend continues and as the company Process optimization
expands and grows the financial losses become staggering. Our
customers typically realize first year reductions of over 61% in Increased customer satisfaction
both scrap and rework while also eliminating customer returns
– all as a direct result of improving the skills and confidence of Quicker changeovers
their workforce. Extended tool and machine life
The Most Advanced Equipment Will Never
Compensate for Poorly Skilled Workers
More energy efficient processes
Despite major advances in technology, machine manufacturers Less employee turnover
have still not eliminated the need for a good, skilled molder. A
strong fundamental knowledge of injection molding is necessary
to properly set-up, troubleshoot, and maintain a repeatable
process.
Do You Underestimate the Cost of Downtime? 5 Typical Excuses for NOT Training
In our experience, managers underrate the impact of downtime Œ ‘If we train them, they will just leave.’
on their company, often ignoring hidden downtime in their
calculations. Downtime is not only the time when the machine is Train one employee and they may leave, train your
idle not making parts. Mold change time, troubleshooting time, entire workforce and you will always have competent
additional cycle time and any time when the machine is producing employees to run your facility.
defective parts also constitutes downtime. Faster mold changes,
more stable processes, and shorter cycle times can easily reduce  ‘I can’t pay for it without a grant.’
this by more than 65%. If you wait for the government to train your employees,
How Much Are Damaged Molds and Equipment they may never get trained. On average, our customers
Costing Your Company? report a three month payback on their training
investment.
Although any piece of equipment can malfunction, smashed and
damaged molds are generally the result of improper handling, Ž ‘I can’t convince management.’
processing, or maintenance. Employees lacking competence
ignore signs of wear or violate good practices because they just Give us a call. We have years of experience in helping
don’t know any better. In most cases, they do not understand companies of all sizes convince management to invest in
the impact of their actions to the company and their customers. training their workforce.
We have found that virtually all employees want to do their jobs
well, but most have never received the skill and confidence ‘We tried training and it didn’t work.’

building tools necessary to do so. Having machine manufacturers and consultants come in
It’s Time to Get Serious About Training for a day and then leave does not constitute a training
initiative.
Investing in professional training demonstrates a commitment
to your employees. Improvements in company loyalty and  ‘I don’t have the time to train.’
morale, as well as reduced turnover, will be clearly evident. A
We offer many different training options that will
commitment to your workforce competence is also an impressive
selling point for both your current and future customers. consume minimal time to administer and facilitate.

tel: (978) 957-0700 email: [email protected]

 Payback Calculator
Scrap & Rework Savings Calculations
A  Enter Actual Scrap Rate Percentage
B  Enter Expected Scrap Rate Percentage
C = A-B  Percentage Scrap Rate Improvement
D =C/A  Scrap Rate Improvement Factor
E  Enter Actual Annual Scrap and Rework Losses (in dollars)
F = DxE  Actual Scrap and Rework Savings

Machine and Labor Savings *

G  Enter # of Machines
H  Enter Hourly Machine and Labor Costs per Machine
I = GxH  Hourly Operating Costs in Dollars
J = I x 6000  Annual Operating Costs in Dollars
K  Enter Actual Downtime Percentage
L  Enter Expected Downtime Percentage
M = K- L  Percentage Downtime Improvement
N = C +M  Percentage Machine Time Improvement
O = N / 100  Improvement Factor
P = J xO  Annual Machine and Labor Savings
* Based on 24 hours a day / 5 days a week / 50 weeks a year

“Since we’ve integrated Routsis’ interactive training into our in-house

training program, we have realized significant results. A 60 percent
reduction in the first year in scrap and rework costs were then followed by
an additional 10 to 15 percent per year over the following 3 years.”
Steve Malinoski
Director of Quality & Engineering
Scitech Plastics Group
West Hatfield, MA

Visit www.traininteractive.com/payback
to use our interactive Payback Calculator

8 www. t r a inint er a ct iv e. co m
Plastics Industry Survey
Reveals Importance of a
Skilled Production Workforce
A comprehensive, industry-wide survey conducted by Plante & Moran, PLLC commissioned by Mid-America
Plastics Partners (MAPP) revealed many statistics and conclusions relevant to plastics manufacturing facilities
such as yours. The following are excerpts from the in-depth report:

Workforce Development
The key is to have an increasingly talented workforce to keep up with the industry’s ever growing
complexity. Treat your workforce just as you would any other asset! Invest in talent wisely and do not
consume talent on low potential activities or customers. Talent should be treated like the rare jewel it is.
(North American Plastics Industry Study - Plastic Processors Report, Plante & Moran, 14, 2005)

Customer Demands
Average number of customers demanding price reductions annually 7
Price reduction percentage granted to customer on average 4.8%
Percentage of new sales requiring future price reductions 36.7%
Customers have requested and received higher price reductions from the molding community. The
impending future price reduction highlights the need for continuous improvement to maintain
profitability. (North American Plastics Industry Study, Plante & Moran, 45, 2005)

Employee Training
Percentage of operators receiving annual training beyond orientation 75%
Number of annual training hours that a typical individual receives 42
Total dollars (direct costs) spent on training per employee per year $215.67
Molding/extrusion is a unique blend of man, machine, and mold/die. We believe you need to have a
balanced investment in all three ingredients to optimize the molding/extrusion process. (North American
Plastics Industry Study - Plastic Processors Report, Plante & Moran, 59, 2005)

Unique Processes
Custom molders that embrace unique processing skills have a higher probability of being better equipped
than the customer to identify new applications of the process. If the process improves the price, form, fit, or
functionality of the product then the custom molder has a temporary advantage over its competitors and
its customer. Examples include, in-mold labeling or assembly, co-injection, multi-shot, etc. Custom molders
with these skills are more apt to look for existing product that can be converted to this process versus
designing new product. The bad news is the process requires significant investment and is only novel for a
window of time before the process becomes mainstream. Process skills and product design skills, while still
important, are not as important as knowledge of the science of molding. (North American Plastics Industry
Study - Plastic Processors Report, Plante & Moran, 71, 2005)

For details on obtaining a copy of this comprehensive,

85 page Benchmarking Survey call MAPP at 317-913-2440,
visit www.mappinc.com or e-mail [email protected].

tel: (978) 957-0700 email: [email protected]

 In-House Training – Making It Work for You
Introducing computer-based interactive training to your facility is the first step. Effective implementation is then
required to significantly increase workforce competence. A structured training plan should be devised to ensure that
the information being presented is relevant and successfully learned. This plan dictates the overall flow of the in-house
training by establishing a realistic pace and does not overwhelm your employees.
Process simulation and supplemental hands-on training can be major contributors in developing a skilled workforce
in a timely and cost efficient manner. Process simulation software is an ideal link between the computer and the
production floor. Participants develop troubleshooting skills by solving defect scenarios on a virtual molding machine
- minus the excess scrap and machine downtime. The employee’s actions are closely monitored, allowing the facilitator
to evaluate their processing skills and make specific recommendations for areas that need improvement.
After an employee has spent some time at the computer training station, he or she should receive focused hands-on
training. This is best done using supplemental task sheets, in conjunction with training materials such as blueprints,
processing guides, and machine manuals.

How to Make Your Training Successful

In order to make your training program successful, the
objectives of each training session should be clearly
defined. Each participant must understand the goal
of the training and how it pertains to his/her job.
The facilitator must direct the training and steer the
How to Make Your Training Fail
participant from one program to the next. A training program can fail for a variety of reasons. The
most common is lack of direction. When the participant
There must also be a way to test a participant’s
enters the room and the facilitator asks, “What do you
knowledge and progress. Test the participant both
want to do today?” the training program is doomed.
before and after a training course. Also, make it easy
The facilitator should have each portion of the training
for the participant to ask questions about each training
program planned, and should always direct the
session. It also helps when each step of the training
participant to the next step. Training plans detailing
provides a reward of some kind. One way is to print
employee tasks (interactive, simulation, job activities)
completition certificates that the participant will
and progress should be posted for everyone to see.
receive after successfully passing the assigned training.
Another idea is to post the names of participants as Lengthy distractions can also derail a training initiative.
each completes a particular course of study. Of course, it is fine when a participant wishes to take
some time to read over a book or manual for more
An effective training program also needs the support
specific information, or to go and look at a piece of
of management. Employees will follow management’s
machinery to see what it really looks like. But these
lead and will develop the same attitude toward training
brief diversions from the planned program should not
that management has. This is why it’s critical to train
take long, and should always serve to enhance the
from the top down.
training program.
A training program also fails when participants lose
enthusiasm. This can happen for a variety of reasons.
Participants need to have their progress measured and
reported, and must be congratulated and recognized
when they complete a program. They must also be
reminded if they fall behind.

10 www. t r a inint er a ct iv e. co m
 10 Requirements You Should Demand from Your Training
Provider and How Routsis Addresses Them
“I need a training provider who is willing to come
“I need training products that apply to what my
to my plant and teach me how to effectively use the
employees actually do here. I want to purchase
training system. We should have a structured plan
what my company needs… and nothing more.”
in place and ready to train before they leave.”

FACT: Most training for the plastics industry is We will show up at your plant, teach you how to get
theoretical and does not apply to your operation… the most out of your in-plant training initiative, and
we guarantee that the products you buy are going to you’ll be training production employees before we’re
improve your operation. out the door.

“I need to ensure that my purchase is supported so

“I need to know the system I purchased will
I can maintain my training system indefinitely and
pay for itself in a timely manner. My vendor
continuously. Good instructional media, such as DVDs
should be able to project some figures so
and manuals, must be provided and phone and e-mail
I can justify such an investment.”
support should be available whenever I need it.”

We are the only in-house training company who We will help you justify the return on investment…
provides instructional DVDs so that the training can If you do not believe your in-house training program
be maintained for years to come, even by your future will benefit your company, we’re more than willing to
employees. implement the training for free and share the returns.

“I need my employees to learn skills that apply

“I need the entire production force to utilize
directly to my workplace. Along with relevant
the training materials we purchase. I also need
training materials, I must also receive supplemental
a training provider who will help me create a
on-the-job training materials to expedite the
training plan to help ensure this happens.”
learning process for each employee level.”

We’re the only in-house interactive training company

We’re the only in-house interactive training company
who provides actual on-the-job training exercises to
who provides an actual structured training plan to
ensure your employees can apply the training they
ensure your employees can actually get trained.
receive.

“I need to be able to implement this training

“I need training that teaches my employees the
system with just the employees I already
best manufacturing practices in the industry. I
have. I do not want to hire more employees
need to know that the information my employees
or send my people out for additional training
learn stresses safety and is up-to-date.”
in order to implement this solution.”

We’ll come to your plant, show you how to make the We will help you establish a set of goals for all your
system meet your specific needs, and create a training production employees… your employees will learn
plan which you can maintain with the employees you and apply the knowledge to your operation so you
currently have. can get the most from your machines.

“I need training that will improve the

“I need to pay a fair price for my training products
attitude and morale of my employees. I need
and services. I don’t want to be hit with any
help convincing upper management to get
hidden fees for things that were not included.”
behind the training initiative, 100%.”

We can help you identify the return on your training

We assure you that you will get powerful employee
investment and convince management so that your
skills development training at a fair price that is
employees will learn to make good parts and really
significantly less than you are currently losing.
care about doing a good job.

tel: (978) 957-0700 email: [email protected]

 Global Standards for Plastics Certification (GSPC)
A. Routsis Associates has teamed up with Polymer Training Limited, UK (PTL) and Mid-America Plastics
Partners (MAPP) to provide the Global Standards for Plastics Certification (GSPC) to the United States.
This comprehensive system is being used in dozens of countries across the world, and is quickly being
accepted and implemented here in the United States. Originally developed by the UK Government in the
1970’s as an apprenticeship qualification, GSPC has evolved through the years to be the most rigorous and
comprehensive certification system available to the plastics industry. This is because certification is based on
an operator or technician clearly demonstrating their ability – not just passing a multiple choice test.

A Standard Tailored to Your Facility

Although the technical aspects of the standard are fixed, a large percentage of the standard is based on
an understanding of your company’s specific procedures and policies regarding production, work relations,
quality, and safety. When employees become certified, it assures the employer that their workforce has
a strong foundation of knowledge, but more importantly the applicable skills which relate directly to the
production environment.

Get Your Entire Production Workforce Certified

GSPC certification is a progressive system which starts at Level 1 and progresses up to Level 3. The typical
candidates for the appropriate levels are as follows:

Level 1 Level 2 Level 3

• Machine Operators • Molding Technicians • Senior Process Technicians
• Material Handlers • Die Setters • Senior Toolmakers
• Quality Auditors • Toolmakers • Process Engineers
• All Production Personnel • Supervisors

How Does the GSPC Process Actually Work?

The GSPC system is a robust system that employs a system of checks and balances to
ensure that your certified employees meet the international guidelines by which the
standard is based. There are three primary people involved in the certification process:
Candidate
Your employees become candidates. The company provides each candidate with their
own workbook to prepare them for certification. Through the aid of training, facilitation,
and existing plant-specific documentation, the employee obtains the knowledge and
competency to fulfill the workbook and ultimately meet the standard.

In-Plant Assessor
As the employee progresses through the workbook, the in-plant assessor periodically
tests and approves the employee’s progress until he/she believes the candidate is ready
to be certified.

Verifier
The verifier ensures the integrity of the standard by visiting the plant and randomly
testing the candidates on the material within the workbook using the production floor
as the backdrop. Once the candidates show complete compliance, they are approved
and receive a certificate for their appropriate level that’s internationally endorsed by
both PTL and MAPP.
Visit www.traininteractive.com/GSPC
to read more about Global Certification

12 www. t r a inint er a ct iv e. co m
 Top 10 Reasons to Become GSPC-Certified
Associations and professions use certification to recognize qualified and competent individuals. The
certification process is one of the single most important steps in career development. Here are the top ten
reasons a plastics professional should consider becoming GSPC-certified.
1. Certification grants you professional credentials. Since GSPC recognizes your individual
accomplishments, it serves as an impartial, third-party endorsement of your knowledge and experience
on both a national and international basis.
2. Certification demonstrates your commitment to the plastics industry. Receiving GSPC certification shows
your peers, supervisors and, in turn, the general public, your commitment to your chosen career and your
ability to perform to set standards.
3. Certification enhances the profession’s image. The GSPC program seeks to grow, promote and develop
certified professionals, who can stand out as examples of excellence in the plastics industry.
4. Certification reflects achievement. GSPC is a reflection of personal achievement because the individual
has displayed excellence in his or her field by meeting global standards and requirements established by
the plastics industry.
5. Certification builds self-esteem. GSPC is a step toward defining yourself beyond a job description or
academic degree while gaining a sense of personal satisfaction.
6. Certification can improve career opportunities and advancement. GSPC can give you the “edge” when
being considered for a promotion or other career opportunities. GSPC clearly identifies you as an
employee who has demonstrated competency in specific technical areas based on accepted industry
standards.
7. Certification may provide for greater earnings potential. For example, in the automotive industry, car
mechanics who have become certified experience salary and wage increases based on their certification
status.
8. Certification improves skills and knowledge. Typically, achieving certification requires training, study
and the demonstration of applicable skills. GSPC showcases your individual competence by confirming
proficiency and knowledge.
9. Certification prepares you for greater on-the-job responsibilities, since GSPC is a clear indicator of your
willingness to invest in your own professional development. Certified professionals are aware of the
constantly changing technology and environment around their profession and possess the desire to
anticipate and respond to change.
10. Certification offers greater recognition from peers. As a certified operator or technician, you can expect
increased recognition from your peers for taking that extra step in your professional development.

è What are people saying about GSPC?

Here’s what some Top Executives are saying about adopting Global Certification for their Operators,
Technicians, Die-setters, Mold Makers, and Supervisors.
“My company needed a training system. The GSPC Certification and Standards system is more than we have ever
dreamed. We now have documented training standards and the latest technology to train our employees on the
technical aspects of their jobs. Above all, we now have a system, governed by an independent body, to verify my
company’s training protocol and test our employees’ progression in improving their knowledge and skills!”
-Rick Green, President, Bourbon Plastics

“This is the missing piece for Metro’s training puzzle. We have been looking for a way to tie certification to all of the
training we do, and GSPC is the answer. This system is well balanced, very comprehensive, and requires employees to
be well rounded; now my employees have a method of building on their technical strengths by learning more about the
business side of the operation!”
-Lindsey Hahn, President, Metro Plastics Technologies

“This certification has teeth, and the content of the standards will challenge production employees at all levels in any
organization. In the years I’ve been in this industry, I’ve never seen a system that standardizes training like this one!”
-Joe Wolf, President, Scottsburg Plastics, Inc.

tel: (978) 957-0700 email: [email protected]

 We Go Above & Beyond the Competition
Routsis is the only plastics training provider who will actually come to your plant.
We’ll ensure that your training investment gets results.
As the premier interactive training provider for the plastics industry, A. Routsis Associates goes above and
beyond anyone else by not only educating your employees, but actually train them as well. We combine
comprehensive interactive training, process simulation, and focused on-the-job exercises for each employee
level at your facility.
We also offer the most extensive implementation assistance in the industry. This includes facilitator
instruction by one of our plastics professionals on how to use, customize, and track the interactive training
system.
We ensure that your training gets up and running quickly and offer support via manuals, instructional DVDs,
phone and email. We will also install and configure the software on your computer at no additional cost. If
you do not have an available computer, we have the latest Dell powered turn-key training stations available.

8 Questions Our Competitors Hope You Never Ask

ΠDo you employ your own plastics professionals that will come to my plant to devise a
structured training plan?
 Do you supply the necessary tools to customize my interactive training?
Ž Do you provide plant-specific on-the-job training tasks?
 Do you have free additional training resources available to all customers?
 Do you provide instructional DVDs to teach your customers how to setup, configure, and
customize the training?
‘ How long have you provided on-site training assistance?
’ How many on-site training assistance visits have your employees performed?
“ Will you provide quarterly reviews of the training progress?

Routsis employs their own plastics professionals who have conducted on-site training assistance to more
than one-hundred plants across the world over the past 4 years. These professionals also provide quarterly
reviews for customers to ensure the training is being used properly and yielding measurable results.
After discussing your training goals and objectives, a structured training plan will be created for each job
position being trained. This comprehensive plan includes interactive training, advanced process simulation
and plant-specific training materials. Customized task sheets are generated to provide workers with focused
on-the-job training exercises to better associate the interactive training with the production environment.
Whether you are just training your machine operators, or conducting a plant-wide training initiative, we can
provide as much assistance as necessary to get your training off the ground – including quarterly reviews.
Learn More About Our Comprehensive Training Solutions: Check out our FREE online presentation entitled
Develop a Fully Skilled Workforce at www.traininteractive.com/skills or contact our office for a set of
demonstration CDs.

Visit www.traininteractive.com/cases
to read Training Assurance Plan Case Studies

14 www. t r a inint er a ct iv e. co m
2005 Skills Gap Report
In 2005, Deloitte Consulting LLP performed a comprehensive
survey of the North American manufacturing industry which derived
many surprising concerns.

Overwhelming Lack of Skilled Employees

The Skills Gap 2005 Survey found that the vast majority of
American manufacturers continue to experience a serious shortage
of qualified employees. This has created a significant impact to
business and the ability of the country as a whole to compete in
a global economy. In fact, 81 percent of respondents answered
that they are currently facing a moderate to severe shortage
of qualified workers. (2005 Skills Gap Report – A Survey of the
American Manufacturing Workforce, Deloitte Development LLC., 4,
2005)

The Need for a High-Performance Workforce “81 percent of respondents

answered that they are
Although many expect that overall employment levels in currently facing a moderate
manufacturing will not rise considerably, 74 percent of respondents to severe shortage of
indicated that having a “high-performance workforce” will be the
qualified workers.”
key factor to their business success. (ibid., 6, 2005)
As the graph below shows, the companies surveyed believed skilled
production workers to be in the highest demand in the future.

The Need to Invest in Training

Employers should invest at least three percent
of payroll whenever possible to provide training
opportunities for their current employees,
particularly in areas that will enable them to
become a high-performance workforce, learn new
methods to attract, retain, develop and motivate
employees. (ibid., 3, 2005)
For details on obtaining a copy of this
comprehensive, 28 page Manufacturing Survey
visit www.deloitte.com.

(ibid., 7, 2005)

tel: (978) 957-0700 email: [email protected]

 Frequently Asked Questions
Why do I need an in-house training program? How do I track my employees’ progress?
Since it’s not logical to send all of your employees away for training, All of our interactive training programs use CourseWorks™ – the
the only viable solution for achieving workforce competence is to delivery, tracking and monitoring software. Pretests and posttests
establish a structured in-house training plan. The most effective can be administered to assess an employee’s knowledge level
way to reduce scrap, excessive downtime, damaged equipment before and after taking a course. Passing scores are assigned to
and customer returns is to improve the skills and confidence of ensure that the participants have retained the information before
your employees. taking another course. CourseWorks™ is ISO and QS compliant,
providing detailed results for outputting and review. Our
What is interactive training? advanced process simulator records every parameter adjustment
Interactive training is a computer-based training method in which made during each troubleshooting exercise and uses a ‘real-time’
the information is presented using animation, digital video, titling, clock to calculate what the actual amount of processing time
and professional narration. During the course, the participant is would be.
asked questions which they must answer correctly before they
can proceed. If a question is answered incorrectly, the information Does interactive training replace hands-on training?
pertaining to that question is shown again to reinforce the topic Although interactive training has many benefits, it can never
being covered. fully replace the need for instruction on the actual production
floor. The drawback is that most hands-on training is typically
Can your interactive training courses be customized? disorganized, causing employees to receive inconsistent and
Yes, our interactive training is extremely flexible and courses limited information. We strongly recommend using interactive
can be easily customized. The facilitator can insert custom text, training in conjunction with focused on-the-job training sessions
digital pictures, audio, and questions. Sections of the courses to keep specific training goals and objectives on track. Our
that may not agree with your plant’s mode of operations can company can provide you with templates for each of our training
be easily turned off. We also give you with a DVD presentation modules.
that provides step-by-step instructions on how to customize our
courses. How will training reduce employee turnover?
We have found that most employees want to perform better
How can simulation software develop troubleshooting skills? at their jobs but lack the skills and confidence to do so. When
Our simulator, PICAT, is a virtual machine that acts and responds supported by management, a structured training initiative
like the real thing. Each simulator provides 64 different defect shows that the company is committed to its employees and will
scenarios in which the employee must make adjustments to undoubtedly increase their morale and loyalty.
the machine, material, or controller to correct the problem,
or problems. As the participant progresses to the complex Is your training up-to-date and relevant?
defect scenarios, they develop a more logical approach to We have the industry’s largest library of interactive courses
troubleshooting as well as more confidence in their abilities. with over 187 plastics training titles. On average, we produce 6
Molding problems can be solved in a faster amount of time and new courses every 12 months. These courses are developed by
processes can also be fine tuned and optimized. plastics experts and emphasize the industry’s best-practices. We
have relevant training materials that cater to virtually any plastics
What support comes with my purchase? company.
All of our customers receive full support. Each customer has the
option to send in their training computer for configuration at no Can interactive training be used in a classroom environment?
additional charge. This includes loading all of the software and Yes, there are many companies and educational institutions using
setting up your training station so all you have to do is plug it in. the software in exactly that capacity. The most effective formula
We also provide setup manuals, step-by-step instructional DVDs, we have seen thus far is when the program is first played over a
and are available via phone and e-mail for both installation and digital overhead projector, and the students are then allowed to
training support. Task templates that correspond to each of the take the training program individually to learn at their own pace.
training modules are supplied in Microsoft Word format as as
sample training plans. Our primary goal is to ensure that your Can the software be networked?
training initiative gets up and running as soon as possible. The software can run on a standalone computer, a local area
network (LAN), or a wide area network (WAN) using one of two
What comes with the “Training Assurance Plan”? configurations. The software can be loaded onto each computer
First, we will fully configure your interactive training station – with a shared database, or loaded directly onto a server. Please
including the installation of all the software and entering all your contact one of our service reps for more information or to discuss
participants data into the program. Second, a plastics trainer will your specific networking needs.
visit your plant and provide thorough instruction on how to use,
track and administer the training. Third, you will be provided with Do I need to hire a facilitator to run the training program?
a digital camera/audio recording device and instructed on how to It is not necessary to hire additional employees to train your
use it for customizing your training courses. Lastly, we will gather workforce when training in-house. We recommend choosing
information about your particular training goals and develop two employees to share the task of facilitating and scheduling
supplemental on-the-job training materials and a plant-specific training. The computer-based interactive training is self sufficient
training plan for all of your employees. and requires no supervision, just a facilitator to periodically review
and monitor participant progress.
Do your courses cover safety?
Our training courses always stress safety and industry best-
practices whenever possible. We also offer a full library of 59
different health and safety courses. Check out our website for
a current list of courses, as new programs are constantly being
developed.
Visit www.traininteractive.com/faq
for more answers to frequently asked questions

16 www. t r a inint er a ct iv e. co m
 Training Courses from A. Routsis Associates
We now have hundreds of interactive training courses available!
è Injection Molding Basics Series (also in Spanish, Mandarin, and Euro versions)
è Production Series
è Advanced Processing Series
è Maintenance Series
è Mold Design and Moldmaking Series
è Plastic Part Design Series
è Health & Safety Series
è SPC/DOE Series
è Blow Molding
è Extrusion
è Blueprint Reading
è Geometric Dimensioning & Tolerancing
è Basic Measuring Tools

Ë New courses are continuously being developed, so check out our website for the latest listing at
www.traininteractive.com

tel: (978) 957-0700 email: [email protected]

w w w. t r a i n i n t e r a c t i v e . c o m

A. Routsis Associates, Inc.

275 Donohue Road, Suite 1
Dracut, MA 01826
tel: (978) 957-0700
fax: (978) 957-1860
email: [email protected]
web: www.traininteractive.com
© A. Routsis Associates, Inc.