Success, with a Surprise Benefit

When we set out to create our first apprentice program for Okuma applications engineers, the challenge was a big one. The learning curve for AE apprentices is typically steep because the knowledge level needs to be extremely high for these individuals to be placed in positions of responsibility out in the field. To reach this level it can take years to fully train and develop new talent.

In today’s marketplace however, everyone needs skilled workers in short order. We at Okuma are no exception. So what we set out to do was what we refer to as “compressing time” for training our up-and-coming AEs.

“COMPRESSING TIME”: 2 TO 3 YEARS DOWN TO 6 MONTHS

In December we wrapped up the training for our first group of AE apprentices and we were astonished at the results. We effectively compressed two to three years of machining experience into a 6-month apprentice program – that’s a huge leap! Moreover, the breadth of the training was comprehensive, and our apprentices were exposed to aspects of machining (e.g. Cpk calculations) that some machinists do not experience in 5+ years in the field. After we reviewed the apprentice’s final presentations, we all agreed – the quality level of the training was quite high. This new program was a success without any shadow of a doubt.

GETTING UP TO SPEED

How did we accelerate and get our apprentices up to speed faster? Over the 6-month program, half of the time was spent in formal classroom training, and half on the shop floor, working with experienced applications engineers on test cuts, customer runoffs, handling workholding, tooling and more. As the experienced AEs worked alongside the new recruits, they developed a great camaraderie, and everyone put a lot of energy into helping each other along the way.

AN UNEXPECTED OUTCOME

As time passed, we started to notice that the experienced AEs started joining in on some of the classroom training, so they could brush up on their skills. This was entirely voluntary on their part, but the result was another great outcome for this program: it made our existing group of AEs, who are some of the best in the business, even better in terms of enhancing their skill sets.

FINAL PRESENTATIONS WERE AMAZING

I want to make sure I share what the day of the AE apprentices final presentations was like, because it was amazing. Attending as observers and evaluators we had some of Okuma America’s top executives in the room, plus a panel of 4 experts who served as “judges.” Talk about pressure…but our apprentices kept their cool.

There were no PowerPoint presentations whatsoever. The way it worked was a lot like America’s Got Talent! Each apprentice stood in front of the Okuma machine they used to produce their part, and described the process, the machine specs, and in some cases, even some documentation. Then the judges would go down the line and provide comments and feedback.

PROVING THEIR PARTS

Each apprentice was required to make a minimum quantity of 30 parts and to calculate Cpk as part of their final exam. They made some interesting parts, as described below:

LOTS OF SUPPORT

There are many people to thank for their contributions to this program. We had lots of support from Okuma partners, including Sandvik Coromant, who hosted an entire week of training at their facility in Chicago. We utilized eLearning resources from SME’s Tooling U. Internally we had major time commitments from project manager Rick Kimmins, our entire team of applications engineers, and of course the apprentices themselves.

A GREAT SUCCESS

In the beginning stages, there was some skepticism about whether this kind of training could be done in 6 months. Applications engineering requires such a broad expanse of knowledge and a combination of scientific skills and artistic vision. Solutions are open to creative interpretation. When our apprentice’s final presentations were complete, those skeptics had been silenced. The reaction in the room was unanimous: what we witnessed was a great success and sets a new standard for our AE apprentice programs going forward. We can’t wait till the next one.

About Jim Kosmala
Jim Kosmala is Vice President of Engineering and Technology for Okuma America Corporation, a world-leading builder of CNC (Computer Numeric Control) machine tools, founded in 1898 in Nagoya, Japan. Okuma is the industry’s only single-source provider, with the CNC machine, drive, motors, encoders, and spindle all manufactured by Okuma. The company also designs its own CNC controls to integrate seamlessly with each machine tool’s functionality.

Company: Okuma America Corporation
Website: www.okuma.com
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