Posts Tagged ‘career technical training’

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Reinventing Education – Students Learning “how to think – not what to think” for New Collar Workforce

Tuesday, August 16th, 2022

Our non-profit Industry Reimagined 2030 has identified some prevailing misperceptions about manufacturing that must be dispelled if we want to be successful in growing the supply of available recruits for manufacturing jobs.  These are that “manufacturing is in inevitable decline” and “manufacturing jobs are dumb, dirty and not well paying.”

Fortunately, the importance of manufacturing during the pandemic and advanced manufacturing technologies are changing some of the longstanding misperceptions. The Deloitte and The Manufacturing Institute 2022 Manufacturing Perception Study reports “Sixty-four percent of consumers surveyed view manufacturing as innovative, up from 39% of respondents five years ago” and 77% now view manufacturing as more important than they did pre-pandemic.

I recently interviewed Glenn Marshall who is one of our advisors for Industry Reimagined 2030. Glenn Marshall is also serving on the Association for Manufacturing Excellence Management team to help lead a Manufacturing Renaissance. He told me that this “initiative is designed to reduce the critical shortage of skilled workers for advanced technology and manufacturing. He reaches out to business leaders, academia, students, veterans, and policymakers to promote innovative ideas to create ladders of opportunity to make ‘Made in America’ a reality by leading initiatives to design and build things at home, again.”

Prior to retiring, he said that he was the benchmarking/process excellence advocate for Northrop Grumman and Newport News Shipbuilding (NNS). He engaged with all levels of the corporation, supply chain, and the Navy and led the proposal team from NNS to support the Navy’s Task Force Lean initiative. He continues to work with NNS in its outreach to the public schools and colleges Career Pathways program.

He said, “We struggled along with other employers in Virginia and across the nation to find the kind of skilled workers they needed so realized that they had to get involved with the local schools. I met with the superintendent of the Williamsburg James City County (WJCC) School District and arranged to have students tour local manufacturing facilities   part of national Manufacturing Day. These employers showed the students, teachers, and parents the kind of good paying jobs are available and what they could earn doing these jobs which got the students interested. 

Then we worked with the New Horizons Regional Education Center (NHREC) in Virginia and other employers to create an expanded   pubic private partnership to provide career and technical educational options for students within the school districts. NHREC is the largest of nine regional centers in the Commonwealth of Virginia.  NHREC has become a benchmark for community partnerships

The New Horizons Regional Education Center (NHREC) in Virginia has engaged in a public private partnership with Newport News Shipbuilding Apprentice School, employers, public school leaders, legislators and families. They are working to provide career and technical educational options for students within the school districts. NHREC has become a benchmark for community partnerships. Educators and families are discovering that career technical initiatives valued by employers can provide an equitable gateway for each student to learn how to be capable of achieving their career goals and dreams.

Glenn commented, “Upcoming graduates will step into a rapidly changing workforce, with a growing number of “new-collar jobs” requiring specialized, technical skill sets. The future of learning is changing — Beyond creating a world online, advances in artificial intelligence, cognitive technologies, and robotics are upending traditional assumptions about jobs and technology’s role in the workplace. For kids wanting to seize these opportunities, having transferable skills will be more important than a degree. For many, a strong foundation in science, technology, engineering, and math skills will be invaluable. And for some, apprenticeship and certification programs will be essential.”

Glenn also sent me information about Virginia’s lab schools. He said, “These schools are partnerships between public and private universities and colleges, as well as private companies and local K-12 schools. Lab schools that have a specific focus, such as STEM or literacy, or a particular skill or industry, will create learning environments that engage students in hands-on learning.”  My research discovered:  “Legislation approved by the 2010 General Assembly (HB 1389 and SB 736) and the 2012 General Assembly (HB 577) allows any public or private institution of higher education in the commonwealth with an approved teacher-preparation program to establish a college partnership laboratory school…College partnership laboratory schools are public schools established by contract between the governing board of a college partnership laboratory school and the Board of Education.”

I told him that California had passed legislation to re-establish career technical education for grades 7-12 in 2002 (Senate Bill 1934 (McPherson), a companion bill to the earlier Assembly Bill 1412 (Wright), passed in the same year) but it didn’t get fully implemented until 2005. Now, I know of three high schools that teach manufacturing skills such as machining and welding in the San Diego region. The training is a two-year program for juniors and seniors and students receive certifications upon graduation.

Glenn said, “Companies want graduates with an eye for detail, creative critical thinking skills, a collaborative mindset and an ability to deal with ambiguity and complexity. New graduates will need foundational skills in reading, writing math and science, but also know how to think – not just want to think.”

He concluded by saying, “To achieve this goal, educators and business leaders must form public-private partnerships and join with organizations like the Association for Manufacturing Excellence (AME), the Reshoring Initiative and others to engage in reinventing the educational experience. The goal is to graduate all students with the critical thinking skills to adapt to the evolving challenges of new-collar careers and the ever-changing demands for the future of work.

The Association for Manufacturing Excellence will host an international conference in Dallas Texas October 17 – 20, 2022.  Register at  https://www.ame.org/ame-dallas-2022  One of the featured sessions will be an international panel discussing how companies are addressing the need to replenish the talent pipeline with skilled career ready new collar workers: 

In order to achieve the goal of creating five million more manufacturing jobs by 2030, we encourage manufacturers to use the increased public awareness to promote manufacturing’s benefits, opportunities, and technological advances to increase the number of youths interested in manufacturing careers. Manufacturers should emphasize that advanced manufacturing technologies now provide, safe, clean working environments that pay well and offer highly transferable skills that enable career advancement.  As incentives, companies can offer internships, work programs, certification or degree programs, and apprenticeships to increase the talent pool and develop the skilled workforce they need to grow their businesses. 

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ToolingU-SME Works to Close the Skills Gap

Tuesday, August 2nd, 2022

The Deloitte and The Manufacturing Institute 2022 Manufacturing Perception Study reports that “ significantly more respondents believe that manufacturing jobs are innovative and more respondents are likely to encourage their child to pursue a career in the industry” [compared to the 2017 study]…”Further, the pandemic has led to a new awareness of the critical nature of manufacturing in the United States and beyond.”

This corroborates the eBook released last year by American Machinist and IndustryWeek titled, “Closing the Skills Gap – How manufacturers are leveraging new technologies and energizing a new generation to finally close the labor gap,” that was sponsored by Epicor Software Corporation.

The Executive Summary stated: “We are on the cusp of a full-scale digital revolution in the manufacturing industry…[and] on the cusp of an enormous wave of retirements as Baby Boomers exit the job market…we have a perfect storm.”  The result could be that the “500,000 unfilled manufacturing jobs today…[could] balloon to 2.5 million over the next decade.”

The eBook outlined the application of the new tactics that manufacturers are applying across industries: “Over the last few years, manufacturers across the industry have begun systematically attacking the skills gap head-on…”

However, now is the time to be prepared to take advantage of the increased interest in returning manufacturing to America and strengthen our manufacturing base as a result of the weaknesses in the domestic supply chain revealed by the COVID-19 pandemic.

Since 1979, the SME Education Foundation has been inspiring, preparing and supporting the next generation of manufacturing and engineering talent through their Student Summit event series, the SME PRIME® (Partnership Response In Manufacturing Education) initiative, and Student Scholarship program. The Foundation “works directly with the manufacturing community to educate the next-generation workforce through SME PRIME. The partnership provides industry-driven and learner-centered curriculum to high school students at SME PRIME schools across the country. Online learning is a significant component to the tailored curriculum developed for each SME PRIME school.”

I had the pleasure of being connected to Chad Schron, who is the senior director for Tooling U-SME and the Co-founder of Tooling U. I learned that Chad grew up in manufacturing. He started his career working in his grandfather’s machine shop and attended his first IMTS show before he graduated from high school. Chad developed the idea for an online manufacturing training school while working at the shop to combat the manufacturing skills shortage.

I told Chad that I started working as an engineering secretary at age 18 for a small defense contractor that was essentially a machine shop making components such as accelerometers, rate gyros, potentiometers before going to college later.

Chad told me that ToolingU-SME has developed curricula that “one in five community colleges and over half of the Fortune 500 manufacturing companies use to train their workforce and their students.” He added, “During COVID we saw significant growth in our education business as schools needed online programs because students were participating online for virtual classes at home.”

From the SME website, I saw that some of the industry-leading companies that work with Tooling-U are: Aerojet General Corporation, B/E Aerospace, BMW Manufacturing Co, Caterpillar, Chrysler Group, Deere & Company, General Dynamics, General Electric Company, Harley-Davidson, Mazak Corporation, Medtronic, Meggitt Aircraft, Raytheon, Senior Aerospace, Siemens, and United Technologies Corporation.

The website states, “Tooling U-SME’s industry-leading online classes and assessments are developed with input from manufacturers and employ the latest methods in instructional design.  “Turnkey Training is a series of predefined online curriculum packages for core manufacturing job roles” that combines classes for targeted learning with on-the -job training (OJT).  “Turnkey Training quickly creates a learning road map and career path for everyone from new hires to tenured employees. Most job roles can be completed in one year with less than four hours a month spent online.”

In addition, “Turnkey Training is ready for immediate use and delivers instruction in the areas needed most by today’s manufacturers. Unlike many other training programs, Turnkey Training requires minimal preparation. It is efficient, effective training that will deliver ROI quickly.”

I asked Chad about the impact of the COVID pandemic, and he said, “COVID impacted a lot of our onsite Instructor led training programs as companies did not allow for in person/onsite training. Most customers have significantly reduced or removed all of their COVID restrictions, and we are back to pre-COVID training programs.”

Chad told me that the COVID pandemic had no real effect on their Apprenticeship and Certification programs. The SME website describes Tooling U-SME’s Apprenticeship Frameworks as “a series of predefined curriculum for common apprenticeship job functions, that provide related training instruction (RTI) using Tooling U-SME online classes…that support common apprenticeship job functions, and provide a flexible model allowing organizations and educators to offer easily accessible solutions in alignment with business needs.”

He explained, “By pairing Tooling U-SME online classes with on-the-job training, trainees can complete their apprenticeships at their own pace from anywhere. Our online classes also provide trainees with the education and theory to help them increase their success. Our Apprenticeship Frameworks are aligned with nationally recognized Department of Labor apprenticeship programs and easily incorporated into a company’s existing programs or used as a foundation for a new apprenticeship program.”

Chad sad that ToolingU-SME also offers Certification programs that “are built by professionals within the manufacturing industry who guide the development and continuous improvement of the bodies of knowledge and competency models upon which the certifications are based.” Current Certification programs listed on the website are:

  • Certified Manufacturing Associate
  • Certified Manufacturing Technologist
  • Certified Manufacturing Engineer
  • Lean Certification (Bronze, Silver and Gold)
  • Additive Manufacturing
  • Electrical Electronics Technology

Chad said, “We are seeing significant grown in our Industry 4.0 curricula as more companies are adopting SMART/Industry 4.0 technologies. This is particularly important as more companies are reshoring and changing their supply chains. They are leveraging these new technologies.”

Chad added, “We have a new Virtual Reality product that we just launched, and there is a video overview to view at https://www.youtube.com/watch?v=g-2MhC3beBY&t=10s and press release to read at https://www.toolingu.com/About/Press-News/Tooling-U-SME-Debuts-Immersive-Virtual-Labs.

He concluded saying, “ToolingU is constantly adding new and updated classes to our online catalog and our upcoming class release schedule can be viewed here.

I told Chad that the training ToolingU-SME provides is crucial to achieving one of the goals of Industry Reimagined 2030; that is, adding 5 million to the manufacturing-related, middle-income workforce by 2030 (a 40% increase.) I told him that I hoped that the ToolingU-SME curricula will expand to being used by four out of five community colleges instead of one out of five to accelerate that rate of training for manufacturing jobs in the U.S. to fill the over 500,000 manufacturing jobs currently open and prevent us from having an unfilled gap of over two million by 2030.

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The Manufacturing Institute Grows FAME’s Technical Training Program

Tuesday, June 21st, 2022

In late 2019, I interviewed Dennis Dio Parker for an article published in early 2020. At that time, Dennis headed up the Federation for Advanced Manufacturing Education (FAME), founded by Toyota as an outgrowth of training that provided for employees when they built their new manufacturing plant for vehicles in Georgetown, KY in 1987. 

I recently reconnected with Dennis and found out the transfer of the program to The Manufacturing Institute had been completed after our interview. He said, “FAME was moved under the leadership of The Manufacturing Institute to gain the infrastructure and network needed to support and grow the program, but Toyota still participates in FAME and uses the Advanced Manufacturing Technician program (AMT) program in its eight manufacturing locations.”

Dennis connected me with Tony Davis, who is now the National Director for FAME USA for The Manufacturing Institute. When I spoke with Tony, he said, “The Manufacturing Institute is the leading advocate for a policy agenda that helps manufacturers compete in the global economy and create jobs across the United States. The MI grows and supports the manufacturing industry’s skilled workers for the advancement of modern manufacturing. The MI does this through diverse initiatives including FAME. The MI is a separate legal entity from the NAM and is a 501(c)(3) public charity.”

The new website states, “FAME provides global-best workforce development through strong technical training, integration of manufacturing core competencies, intensive professional practices and hands-on experience to build the future of the modern manufacturing industry.”

Tony said, “FAME currently has 37 chapters in the following 13 states:

Tony explained that the chapters denote a collaboration of employers with an Economic Development Corporation or a Chamber of Commerce with a community college or university.  He said, “the Advanced Manufacturing Technician (AMT) program administered under the FAME model leverages a work/learn framework to weave technical knowledge, professional behaviors, and distinct manufacturing core exercises into a focused co-op experience to build global-best, entry-level, multiskilled technicians.”

He said, “FAME is the premier advanced manufacturing workforce education and development program, helping students become highly skilled, globally competitive, well-rounded and sought-after talent that can meet the unique needs and challenges of today’s modern manufacturing workforce.”

I asked what are the requirements for students, and he said “Candidates for FAME should be career-oriented, academically prepared students seeking rewarding work.  All participants must be high school graduates who are ready to participate in a highly regimented, hands-on programs and are aiming to advance quickly in their career. The program consists of five semesters after which the graduates have a debt-free degree as an Advanced Manufacturing technician.  Every year, FAME graduates transition into well-paying, diverse career pathways in critical disciplines across the manufacturing industry and across the country.”

I told Tony that I have written about how important I believe Lean training is critical to rebuilding American manufacturing and is important to enable American companies to become more competitive in the global marketplace.  I asked Tony if the AMT curriculum incorporates Lean training, and if so, how  does it do it?

Tony answered, “There are five core topics in the five-semester curriculum and each core topic incorporates core aspects of Lean:

  1. Safety culture
  2. Visual Management and 5S (housekeeping)
  3. Lean principles and practices
  4. 8-step problem solving
  5. machine reliability

He added, “In the first semester, students make a personal safety commitment that they must always include when giving their personal introduction.  This is part of the learn and live it model of the program. The program uses a mix of lectures, college-level activities, employer activities, and real, added value solutions in project-based exercises. The program also ties in professional behaviors, such as timeliness, dress code, grooming, posture, and working as a team.”

I mentioned that I had noticed the FAME Live event that was held May 24-25 in Louisville, KY. He said, “This was the first live event since 2018.  It is a day-long learning event in which attendees meet and hear from students, instructors, and graduates, as well as employers and community partners to understand how each stakeholder plays a part in making these programs successful. The day allows interested stakeholders to leave with a strong understanding of the model and with solid action items to help them implement this solution to meet the growing demand for skilled workers.”

I asked Tony if FAME is still partnering with Project Lead the Way (PLTW) that I had mentioned in my previous article.  He replied, “We know the vital importance of a pipeline of preparation into programs like FAME AMT, and continue to encourage local partnerships between chapters and programs in their respective schools systems, programs like Project Lead the Way and FIRST Robotics. Industry tours through broad support of initiatives like MFG Day make a huge difference, too, in the awareness of local students relative to opportunities in manufacturing near them.

And of course, we are always exploring new ways to better attract and engage more diverse audiences into manufacturing, whether into programs like FAME AMT or into other manufacturing roles such engineering, technology, management, etc. The MI continues to be a thought leader around DEI in manufacturing and we carry this effort into our chapter training and communications.”

At the end of my interview, Tony said, “We are always looking for industry partners to help expand manufacturing education opportunities to talent across the country. If you are an employer, business leader, city official or industry association interested in learning about the FAME model, joining a FAME chapter, or starting a new FAME chapter, contact our team at FAME@nam.org or schedule an informational session.

I thanked Tony for the information he shared with me and told him that the kind of training FAME provides is crucial to achieving one of the goals of Industry Reimagined 2030; that is, adding 5 million to the manufacturing-related, middle-income workforce by 2030 (a 40% increase.) I told him that I hoped FAME will expand to more states in the West in the near future.

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How has the COVID Pandemic Affected Makerspaces?

Wednesday, November 4th, 2020

In the past several years, I have visited four makerspaces in southern California, and I recently decided to see how the COVID pandemic had affected these facilities.  Makerspaces play a role in reviving the entrepreneurial “maker spirit” necessary to rebuild and grow American manufacturing.  

The first center I had visited several years ago was MakerPlace, located in San Diego, California. MakerPlace was founded in 2012 by Brian Salmon, Michael Salmon, and Steve Herrick. It was touted for its promising concept of a shared “dream garage,” where hobbyists or professionals could use high-end tools and industrial equipment to make their creations. It had equipment for metalworking, electronics, embroidery, sewing and specialty tools such as laser cutters and engravers.  It also rented out studio and office space, making it a sort of workshop/coworking hybrid.

When I called to talk to the owner, I was unable to connect, so I searched online and found two articles in the San Diego Union Tribune. The first article from December 6, 2019 said that the sole remaining business head of the company, Steve Herrick “decided he was ready for retirement and sought a buyer.” In December 2019, Joseph Henseler and his wife and partner, Lorena Isabelle took over as the new owners.  Hensler had ran his construction and design firm, Duende out of the MakerPlace for six years.

The second article, dated February 2, 2020, stated that MakerPlace “has abruptly shut down, asking members to remove all their belongings in less than 10 days. The shop sent an email to its members with few details about the closure. ‘MakerPlace is officially closing,’ the email reads. The building will be open “only for picking up your own personal items/tools/materials. Anything that’s not picked up by Feb. 14 will be forfeited.” The announcement of the closure came as a shock to members, and some had paid in advance for months of use.

Since the announcement of the closure occurred prior to the shutdowns for the COVID pandemic, it is likely that MakerPlace closed for financial reasons not caused by the pandemic.

The second makerspace that I had visited on Manufacturing Day in October 2016 was Open Source Maker Labs (OSML) in Vista, California.  OSML is the only makerspace in North San Diego County.  Dan Hendricks opened OSML in 2013 to provide a high-tech digital fabrication lab where members can learn, collaborate, innovate, design, and build almost anything.  Their lab is filled with open workspace and tools:  electronics, CNC machines, 3D printers, laser cutter, panel saw, press brake, welding and soldering tools, drawing and modeling programs, and a computer lab.

When I spoke to Dan last week, he said they closed down for two weeks until they realized they fit the definition of an essential business that was allowed to stay open under Governor Newsome’s order. 

I asked what he has had to change.  He said, “We follow the stage 2 guidelines and limit the use of our labs to members by appointment only and limit the number of people based on our square footage. We practice a smart sanitization routine for our Maker Lab. We only lost a couple of older members worried about their health, but have picked up some new, younger members. We haven’t had to turn anyone away.  We focus on R&D technology and have a lot of the software needed for designing new products.  We offer a co-working incubator-type atmosphere for startup and existing small to medium-sized companies.”

He added, “I’m an Adjunct Professor at Cal State San Marcos, so we are doing some online classes in partnership with the college. I will be doing an online class on IIoT for the next term.  Our strategy was to ride out the pandemic and not change to be ready to help with the recovery and support the new companies that will form during the recovery and provide R&D resources for existing small and medium sized companies to do their R&D at our facility.

In 2016, I also visited Vocademy – a Maker Space in Riverside, California, founded by Gene Sherman. Vocademy was a combination of the “best parts of makerspaces, school shop classes, trade schools, R&D labs, and dream garages, all in one place. His dream was “to solve the skills gap for the manufacturing industry.” Unfortunately, it was Sherman’s focus on providing shop classes for schools and being a vocational trade school that made Vocademy an early casualty of the COVID pandemic so that it closed down on March 20, 2020 after Governor Newsome ordered all schools and non-essential business to shut down because of the COVID pandemic.  An article in the Press-Enterprise of March 28th, stated: “Vocademy…can’t afford to stay open due to the state order mandating business and school closures, wrote Gene Sherman, the nonprofit’s founder and CEO.

The academy partners with schools, and when those schools closed until next school year, 70 to 80% of Vocademy’s revenue was lost, Sherman said in an email.

In addition, many of our current students did not wish to attend class and other potential community students told us they will not be signing up because of virus fears, Sherman wrote. “We are a small business and, unlike a public school, our revenue does not come directly from educational funding.”

It broke my heart to hear that Vocademy has closed because providing vocational shop classes to youth is critical to providing the next generation of manufacturing workers need to rebuild American manufacturing.

I had visited Urban Workshop in May 2018 after attending a conference. The Urban Workshop Is located in Costa Mesa and was founded by and is privately owned by, Steve Trindade. The 28,000 square foot floor plan includes workshop areas for a variety of manufacturing processes, co-working office space, a work assembly area with assorted hand and power tools, storage space for work in process and materials for members, a conference room, a large meeting room, and a retail store offering convenience materials and consumables.

When I interviewed Steve last week, he said, “We were closed for 60 days before re-opening. I sent a heart-felt message to members and most of them continued to pay their membership dues and monthly charges for storage space. We told them we would make it up at the end after we reopened. We lost our hands-on contract work with a charter school, but we were able to make 50 videos for their online education program.”

He explained, “What saved us is that we have four different revenue streams:  membership dues, fees for storage space for members, fees for classes, and co-working space. We made some decisions early on that were based on my experience in ramping up and down for the racing industry I was in previously. We went down from 330 members to 180 members, but went back up to 335 members within 80-90 days of reopening. We implemented a stringent sanitizing program and members have to make appointments”

He added, “We are continuing our program to license our operational procedures and class documentation to other makerspaces as a “Maker Space Blueprint,” provide operational training in setting up and running a makerspace, and provide instructor training to enable them to succeed and prosper.”

I told him I was glad they have survived the effects of the pandemic because makerspaces play an important role in rebuilding American manufacturing.  We agreed that new businesses will be formed by people who have lost their livelihood during the pandemic just as previous recessions spurred the formation of new businesses

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FAME Develops World Class Manufacturing Technical Talent

Tuesday, February 4th, 2020

Over the past several years, I’ve written nearly 30 articles about programs that address the shortage of skilled manufacturing workers. Last Friday, I had the pleasure of being connected by a friend to interview Dennis Dio Parker, who heads up the Federation for Advanced Manufacturing Education (FAME). The purpose of FAME “is to be the driving force for developing global-best technical talent for manufacturing and other employers of technical workers.  FAME strives to be a powerful conduit between industry and education.”

Dennis told me that according to the 2018 Deloitte and The Manufacturing Institute Skills Gap and Future of Work study. “The Fourth Industrial Revolution is transforming the world of work through artificial intelligence, advanced robotics, automation, analytics, and the Internet of Things. Despite common fears, these technologies are likely to create more jobs than they replace—as illustrated by the tight labor conditions in the US and global manufacturing industry.”

While there was a shortage of about 500,000 unfilled jobs in 2018 due to the skills gap of manufacturing workers, the “study reveals that the skills gap may leave an estimated 2.4 million positions unfilled between 2018 and 2028, with a potential economic impact of 2.5 trillion.” The reason why 2028 is a watershed year for the age of workers is because the last of the Baby Boom generation (1946-1964) and the first of Generation X (1961-1981) would be starting to retire.

Dennis explained that the FAME Advanced Manufacturing Technician Program was an outgrowth of training that Toyota Motor North America provided for employees when they built their new manufacturing plant for vehicles in Georgetown, KY in 1987.  Dennis was one of the first 13 trainers hired to start the training in 1987 and he is the last one still working of the original 13 as he transitions to support transfer of the program after The Manufacturing Institute and Toyota Motor North America announced a partnership to hand-over operation and stewardship of FAME in September 2019.

Dennis added, “Toyota had the advantage of having a culture of continuous improvement, and we continually improve the program. The original vision was to have the training program set up at eight locations where Toyota has a manufacturing presence in North America. We wanted to have other manufacturers as partners in these regions to create a pool of skilled workers for all.  Part of our goal was to help solve the problem of the lack of skilled workers, but the problem is too big and endemic for one program to solve.  There are a lot of good programs, but FAME is different from the others in the way it is structured. This is an employer-led program, not an education-led program.”

When I asked how the training expanded out of Toyota, he said, “In 2005, Ernie Richardson and I made a proposal to Keith Bird, Kentucky Community Technical College Chancellor and Jim Kerley, BCTC President to build a new community college in Georgetown to introduce a new education program. The new campus design was established at NAPSC in 2006 and began operation with the first students in 2007.

With the campus in place, we completed development of the Advanced Manufacturing Technician program establishing an employer group to participate in it. I contacted Ken Carroll, then V. P. of the Kentucky Association of Manufacturers, and worked with him to develop an employer collaborative to support the AMT program. We held the first discussions with other companies in 2008 – 2009, and by October we had formed an organization and elected officers. The first name was the Bluegrass Manufacturing Development Collaboration. (B-MDC)”

He explained why the program stalled, saying, “The Great Recession hit full force in 2009, and we decided to be inactive until business conditions improved. However, Toyota began the first AMT training class in August 2010 at the new campus. By 2011, business conditions had improved to the point that Ken and I decided that it was time to restart the B-MDC. On September 29, 2011, the group met again. We had invited a number of special guests to help relaunch the effort, including Jennifer McNelly, president of the Manufacturing Institute; Wil James, president of Toyota’s Kentucky plant; Dr. Vince Bertram, national president of Project Lead the Way; and Dr. Stanley Chase, a national expert on educational collaboration with business and industry. Since that meeting, the employers group supporting the AMT Program has been in continuous operation.”

Continuing, he said, “Other companies sponsored their first students in the AMT Program with the class of 2012 when 3M, Central Motor Wheel Manufacturing, and GR Spring added their students. In March of 2013 the re-born B-MDC elected new officers, installing Terry McMichael of 3M as President and Danette Wilder of SealingLife as Vice President.”

When I asked how the name was changed to FAME, he said, “The West Virginia Toyota plant started the AMT Program with their college and in close partnership with the West Virginia Manufacturers Association (WVMA). When West Virginia governor announced the start of the AMT Program, he also announced “WV FAME” as the name for the future group of manufacturers which would support AMT in West Virginia.  The “FAME” name was immediately recognized as a powerful promotional identifier for the whole Advanced Manufacturing Career Pathways effort, and with permission of the WVMA, we adopted FAME as the name for North American use, and the B-MDC voted to change the name of the group to KY FAME.”

He added, “On January 14, 2014, Governor Steve Beshear announced the formal incorporation of KY FAME as a state-wide organization with a state board of directors to guide it and direct support of the Kentucky Cabinet for Economic Development. The Kentucky Community and Technical College System adopted AMT as a state-wide degree track, available anywhere that a local FAME chapter formed. a KY FAME chapter.

Dennis expressed that the results of the training were so compelling that the FAME sites became a destination for educators and educational researchers, business and industry, and news organizations. The AMT programs in Kentucky began contributing to research and study efforts, and had over 1000 visitors from across the U.S. and six foreign nations.  It was judged by many national educators and workforce leaders to be the best 2-year technical program in the U.S.  

He said, “The results of the program and the publicity fueled the growth beyond what Toyota ever expected. It became more than what Toyota could effectively support.  Toyota wanted to maintain what they had, but wanted to establish it on a long-term basis. This is what led to the program being transitioned to management by The Manufacturing Institute. In order to help make this transition successful, I am now on assignment by Toyota for the next few years to manage the transition.”

Dennis explained, “There are currently 403 participating companies at 34 community college campuses and four universities in 13 states, and the numbers are growing every year. The reason for the success is that the employer, not the student, is the number one customer and the profoundly higher outcomes of FAME AMT graduates compared to traditional graduates.  The program incorporates the six professional behaviors, the seven essential behaviors, and the five professional practices, all soft skills, in addition to the manufacturing core exercises that are based on five Lean manufacturing practices.  As a result, the program provides globally competitive technicians that support the success of U. S. manufacturing. The program is a core pipeline for students to continue to Advanced Manufacturing Business and Advanced Manufacturing Engineer degrees. In the AMT program, students go to school three days a week, and work for their sponsoring manufacturer two days a week.  The students are paid for their work, and the student makes enough to pay their tuition, so they can graduate without any student debt.”

He elaborated on future strategies by saying, “We want to proactively change the equation for technical career pathways.  We have been partnering with Project Lead the Way (PLTW) to engage PreK-12 students in the career pathway because they have a comprehensive, seamless, and coordinated PreK -12 program nationwide.  Toyota and others are already providing plant tours to high school students in PLTW programs.  Currently, the PLTW national office supports FAME with development or material and other engagement activities and FAME supports the PLTW national office with PR and involvement with activities on a regional basis.

We also partner with the National Alliance for Partnerships in Equity (NAPE) because they focus on encouraging young woman and minorities to choose STEM careers.  Their “Make the Future” program, developed at our request, is connecting girls to manufacturing.”

I told him this topic is dear to my heart as I have been a woman in manufacturing since starting as an engineering secretary at age 18. I concluded the interview by saying it was a pleasure to learn about FAME and hope that it will expand westward in the future all the way to California where I live.

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How the STE@M™ Mentoring Program Helps Students Focus on Manufacturing Careers

Tuesday, November 13th, 2018

MFG Day gets better every year and is inspiring youth to pursue careers in manufacturing. In California, Governor Brown even proclaimed the month of October as the Manufacturing Awareness and Appreciation month. However, MFG Day only occurs once a year.  How can we help keep students focused on pursuing careers in manufacturing throughout the year?

 

One way is the STE@M™ Mentoring Program developed by Cari Lyn Vinci of InVINCIble Enterprises to train educators and youth leaders so they can motivate the next generation of students. InVINCIble Enterprises’ award-winning STE@M™ Mentoring Program is based on the book, Playbook for Teens,. about which I have written previously.

Through the STE@M™ Mentoring Program, teens learn how an interest in STEM subjects translates to opportunities in STEM careers. The Program helps students answer two age-old questions:

  • “Why do I have to learn that?” and
  • “What am I going to do when I grow up?”

The Program is used in middle and high schools as an after school, pull-out during class time, lunch-time, or club activity. The Program takes a group of students through 8 – 24 sessions (called Master Minds) focused around STEAM topics with local guest speakers. Master Minds are paired with POWER skills like public speaking, leadership, critical thinking, communication and collaboration. Students visualize being CEO’s of their lives, contributing to society as business owners, leaders, and workers in STEM industries.

The program incorporates team building and a reflection process, and students discuss how to apply what they are learning to their own lives. Students experience real networking opportunities and mentoring from adults and from each other. The outcome is that students create their own Playbook for Success with one of four goals after high school:

  • Community College or Trade School
  • 4-year or advanced degree
  • Military
  • Apprenticeship or an alternative goal that includes education

The program concludes with a Celebration that involves students presenting their own Playbook for Success while letting parents, educators, and peers know what help they need to achieve their chosen goals.

In an email to his educator network, Gary Page, Education Programs Consultant for the Career Technical Education Leadership Office in Sacramento, wrote “The STE@M™ Mentoring Program provides professional development training and resources to implement a guided, well-articulated career education program. Because the program reflects the Community College’s STRONG Workforce standards, Vinci was recognized by the California Chancellor’s Office as a STRONG Workforce Champion.”

The STE@M™ Mentoring Program supports:

  • New World of Work – 21st Century Skills
  • STRONG Workforce Initiative
  • California Guided Pathways
  • Common Core and Career Technical Education (CTE) Model Curriculum Standards
  • CA After School Network Quality Standards
  • National Career Development Guidelines.
  • California Department of Education Standards/California Common Core ELA Standards

Through Professional Development of educators and professionals, this award-winning Program is being introduced to students in schools and by non-profits who serve middle schools and teens throughout California. This training is within the California After School Network Power of Discovery System.

When I interviewed Ms. Vinci last week, she said, “We started to facilitate Professional Trainings on the STE@M™ Mentoring Program in August 2016. These were sponsored by the Small Business, Deputy Sector Navigators Doing What Matters grant from the Chancellors Office. Trainings have taken place in Fresno, Merced, Monterey, Mt. Shasta College/Eureka, Oceanside, Sacramento, San Diego, San Joaquin, San Luis Obispo, Stockton, Ventura, and Woodland.

When educators implement the program, they reach 15-25 students in each “MasterMind” session. As a result, we have impacted over 7,000 students, parents, and teachers.

In addition to the California Chancellor’s Office STRONG Workforce Champion recognition, we have been acknowledged by the National Association of Women Business Owners with their Visionary Award; by Soroptimist with a RUBY award; and Program of Excellence from the Woodland School Board & the Yolo County Office of Education.”

She explained, “We are partnering with PRO Youth and Families non-profit organization in Sacramento for a proposal to train 300 Educators in 29 counties, spanning seven regions in the California County Superintendents Educational Services Association (CCSESA), which would impact over 6,000 youth.

We also have a media partnership with Diversity in STEAM Magazine. When we are invited to speak at conferences, meetings, and trainings, we provide a complimentary hard copy of the magazine and a free 1-year digital subscription. www.diversitycomm.net/inVINCIbleEnterprises

Diversity in STEAM Magazine (DISM) is dedicated to the advancement of all minorities, women and K-12 students within STEM. DISM provides and informs cutting edge concepts and is the link between the qualified students, career and business candidates, educational institutions, corporate America, and the federal government.”

In conclusion, Ms. Vinci said, “We are connecting the dots in the Woodland School District – where we piloted the STE@M™ Mentoring Program in 2016. This past August, the California After School Network (ASES) coordinators and their tutors were trained to bring the STE@M™ Mentoring Program to their 5th and 6th grade students. The goal is to bridge the gap and keep students motivated about STEAM careers as they transition from middle school to high school to an education after high school.”

Ms. Vinci explained that the training is a full day and includes:

  • Printed curriculum materials
  • Professional Development Training Guide for 8 – 24 session STE@M™ Mentoring Program with detailed Lesson Plans, Student Handouts & Teacher Resources
  • Planning checklists for MasterMinds and Celebration
  • Print Playbook for Teens
  • All Educators receive Playbooks for their first group of students
  • Digital Access to:
    • PowerPoint presentations for all sessions + Celebration
    • PDF version of Training Guide
    • Additional Resources & Updates
  •  Implementation Support:
    • Educators receive on-going phone support and one mid-point virtual coaching session.
  • Guidance to personalize the Program for their sites
  • Assistance identifying guest speakers and phone mentors
  • Invitation to STE@M™ Mentoring Program LinkedIn Group and Facebook

The most recent STE@M™ Mentoring Program PD Training was held in October in Ventura.  Gayla Jurevich, the Small Business & Entrepreneurship DSN with the California Community College STRONG Workforce, sponsored the event for educators from Kern, San Luis Obispo, Santa Barbara & Ventura Counties. Jeff Hamlin, the STEAM Hub Lead for Expanded Learning at the Ventura County STEM Network was the other co-host.

After the event, Ms. Jurevich said: “What I love about the STE@M™ Mentoring Program is that it reinforces the STRONG Workforce Goals and encourages girls who have an interest in STEM subjects to visualize the possibilities. Instead of losing interest in middle school (which many girls do) the program encourages them to continue on a pathway to a STEAM career.”

Jeff Hamlin commented: “Ventura County is excited to bring the STE@M™ Mentoring Program to our After-School Program because it raises the bar of quality of our programs, plus it aligns with the California After School Quality standards.

Research tells us that kids are deciding as early as 5th grade if they like science or math. That decision closes the door to future career opportunities in the growing STEM industries. For that reason, it’s important that students see the potential early. Also, the program incorporates 21st Century skills like communication, collaboration & critical thinking. These skills are beneficial for students regardless of their future career choices.”

Here’s what Paisley, an 8th grade student at Twelve Bridges STEAM Middle School, Lincoln, CA, said at her group’s Celebration, “I plan to have a career in sports medicine. I know this is right for me for me because it fits all the parts of the Career Sweet Spot™ that I read about in my Playbook for Teens. Sports Medicine will use my talent for science; it fits my outgoing personality to help patients; the market outlook shows potential for growth, I have a passion for helping people; and the investment in my education shows promise because sports medicine is a growth industry.” (To see how students are benefitting from the STE@M™ Mentoring Program, please watch their transformation in these videos)

Here’s what Ted Ruiz, a one parent of one of the girls who went through the mentoring program held in Woodland in 2017 wrote, “As a parent of a teenage girl I want to make sure my daughter has every opportunity to succeed. When I learned my daughter was invited to participate in the Play Book For Teens /STE@M mentoring program I thought it would be a great way for her to be exposed to new career paths. At the completion of the program I realized the program was much more than simply learning about STE@M.

The girls in this program learned soft skills that are not provided in any other setting. The networking, researching, interviews, camaraderie, and interactions learned through the program are not taught in our current “teach for the test” educational setting. The girls who participated are years ahead of their peers when it comes to soft skills. Not every girl will be a rocket scientist or doctor, but every girl will need to know how to interact with strangers, present themselves professionally, and collaborate to be successful in life. As a parent I wish programs like this were mandated for all student.”

Ms. Vinci will be presenting at a Pre-conference workshop on November 28, 2018, “Building an Equitable 21st Century Workforce – Starting Early & Nurturing the Pipeline from K-12 to Careers from 1:00 – 2:30 PM; “Peek into the future – get an understanding of why and how the workplace has changed and where it is headed. This TED-talk panel discussion encompasses points of view from educators and business people on the important tools and practicality of building a STRONG workforce.”  This pre-conference session is the day prior to the California Perkins Joint Special Population Annual CTE Equity and Access Conference November 29-30, 2018 in Sacramento, CA.

Can you imagine what our schools and communities would be like if all students had such clarity of purpose for their future careers?  Ms. Vinci has the goal of expanding this mentoring program across the country. This type of mentoring program would go a long way towards filling the pipeline of workers needed in the manufacturing industry as well as other STEM industries.

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MFG Day Motivates Youth to Pursue a Career in Manufacturing

Tuesday, October 23rd, 2018

Since 2012, thousands of manufacturers around the country open their doors to inspire and recruit the next generation of manufacturers on Manufacturing Day (MFG Day), which was held this year on Friday, October 5th.

MFG Day is produced by the National Association of Manufacturers and the Manufacturing Institute. MFG DAY had ambitious goals: “to change public perception of manufacturing, inspire students to pursue manufacturing careers, and strengthen the future of manufacturing by avoiding the talent shortage on the horizon.” According to the MFG Day website, “We wanted to correct the idea that manufacturing involved repetitive, unskilled tasks that happened in dark, dirty factories — a ridiculous idea to anyone who has actually worked in manufacturing — and show people what manufacturing really looks like.”

Those of us in the industry know that today’s manufacturing jobs are high skilled, and take place in clean, well-lit, technologically advanced facilities. The problem was that there was no way to know whether perceptions were changing until Deloitte became a sponsor of MFG DAY in 2015 and conducted surveys of attendees.

The results of the survey of 2015 showed:

  • 81% of students emerged “more convinced that manufacturing provides careers that are interesting and rewarding.”
  • 62% of students were “more motivated to pursue a career in manufacturing”

The 2016 survey results showed that the percentages rose to 84% and 64% respectively.

The 2016 Deloitte report said, “Projections indicate that roughly 600,000 people attended MFG DAY events in 2016 and that 267,000 of them were students. That means that nearly 225,000 students walked away from their MFG DAY 2016 event with a more positive perception of manufacturing, according to Deloitte’s findings…. Based on the 267,000-student attendance figure, that’s potentially 171,000 new members of a next-generation manufacturing workforce.”

The Deloitte surveys showed that “71 percent of student attendees both years said that they “were more likely to tell friends, family, parents, or colleagues about manufacturing after attending an event,” meaning that they weren’t just convinced — they were inspired.”

This year, the MFG Day website listed 2,739 events planned across the country. In California, there were events planned at more than 250 locations throughout the state. The CMTC October 9th newsletter stated, “This year, CMTC and its California’s Manufacturing Network were much more active in sponsoring, organizing and coordinating events statewide. CMTC was also very committed in pairing up schools wishing to attend Manufacturing Day events with manufacturers and other organizations hosting open houses, career fairs, and expos. CMTC and its California’s Manufacturing Network’s efforts directly resulted in over 50 schools attending these events. At these events, students received first-hand exposure about today’s manufacturing technologies in industries that employ highly-skilled and well-paid individuals while offering exciting, rewarding, innovative work environments.”

Since I moved up to Hemet, CA in September, I attended events in Riverside County instead of San Diego County.  There were five events in the city of Riverside, one in Menifee, one Murrieta, one in Perris, and one in Redlands.  This is in comparison to my former home county of San Diego with 22 in the city of San Diego, three each in Carlsbad and San Marcos, two in El Cajon, and one each in Chula Vista, Oceanside, and Vista.

I attended only three events in Riverside County because they were located so far apart, and most of the events were held in the same time period between 10 AM and 2 PM. I began my day by attending the event in Menifee at Mt. San Jacinto College to introduce their new Makerspace to students.  The auditorium was nearly filled with students form Santa Rosa Academy where a panel of business professionals and professors shared the value of their education to their careers.  The event was sponsored by the City of Menifee, the Menifee Valley Chamber of Commerce, and CMTC. The audience was welcomed by Major Bill Zimmerman and Tony LoPiccolo, Executive Director of the Chamber.

Fortunately, I was able to get a private tour of the MakerSpace by Hal Edghill, the MakerSpace specialist, before the students had finished listening to the panelists. The MakerSpace has 15 inexpensive 3D printers and two more advanced 3D printers for students to use for their projects, as well as a small laser cutter/engraver. Mr. Edghill said the MakerSpace just opened in August, so this is the first semester it is available for students to use for projects.

There were so many students that they were divided into four groups for their tour.  Afterward, the students enjoyed pizza and soda before returning to school.

I then drove up to Riverside for a tour of Aleph Group, Inc. (AGI). AGI builds custom bloodmobiles, mobile medical and dental clinics, container hospitals, emergency command vehicles, mobile command centers, and specialty trailers, modular units, and vehicles.  Founder and President/CEO Jales De Mello conducted the tour personally, and we saw four projects in various stages of construction.  One bloodmobile was completed, ready to ship to Saudi Arabia.  Another nearly completed project was a mobile medical/dental clinic being built for a northern California Indian reservation.  The largest project under construction was a modular clinic.

Mr. de Mello said, “I started the company in 2001 with the goal of “making a positive on people’s lives. Our mobile health clinics are custom designed from the ‘ground-up,’ and are fully equipped for turnkey operation. Sizes range from 28 ft. up to 50 ft., and all of our vehicles and units are 100% wood-free construction, so as to eliminate all possibilities of bacteria and fungus growth associated with the use of wood products. The all-aluminum construction is lighter weight, has greater performance and longevity, and improves fire safety.” He believes that “his industry and its leaders must take a proactive approach in solving the needs of mankind.”

Next, I drove to Phenix Technology, Inc., which manufactures high quality fire helmets and other fire safety products and collectibles.  I arrived early for my 2:00 PM tour, so while the formal tour of manufacturing was being conducted, I had the pleasure of getting a private tour of their collectible museum of fire helmets from around the world and memorabilia related to fireman and fire stations. Museum tours are available upon request.

Phenix Technology, Inc was founded in 1972 by Former California State Fire Marshall, Ronnie Coleman and former Assistant Chief of the California State Fire Training Division, Ray Russell to make higher quality fire helmets. Four decades later, Phenix is still a family business who continues to proudly manufacture in the USA, and Mr. Coleman and Mr. Russell “are still there and available to answer any questions you might have about firefighter head protection.”

Tyler Meyer conducted the formal tour, and I saw three different styles of fire helmets being made in the production area.  Tyler said they have gone through Lean training and greatly improved their productivity and reduced lead times.  He said, “We can now make up to 20 helmets per hour instead of four.  Our lead times for most of our products, except for handmade leather helmets. went from 6 weeks to 6 hours in some cases. Our sales went up 51%, and our Net Operating Income went up 1600%+. We reduced our inventory by over $100,000, and our inventory turns are almost unmeasurable as we do everything just in time. We haven’t had any significant price increases in three years though our COGS increased as much as 30% because our controllable costs are down.”

He referred me to their Director of Global Operations, Angel Sanchez, Jr., who emailed me that “it is more important to talk about how Lean has created a culture of continuous improvement and total employee engagement. How Monday is most of our people’s favorite day of the week, not Friday. How we have learned that Lean is about creating a mindset where you see waste in everything and how everyone works together to eliminate it. If you are encouraging people to start a Lean journey, the focus has to be on the pillars of Lean, not the metrics.”

I was happy to get another example of the difference a Lean transformation can make in company performance and how important it is for American companies to become Lean enterprises to help rebuild American manufacturing.

I encourage more manufacturers to plan to participate in MFG Day in 2019.  Open your company to a tour.  Invite the families of your employees.  Invite your customers.  Invite the students of local high schools.  Invite your elected officials.  Many of them have never been in a manufacturing plant.  Let’s make 2019 the most successful MFG Day to date.

 

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Training for Skills and Lean are Important to San Marcos Region Companies

Wednesday, July 11th, 2018

My time in San Marcos, Texas included visits to more traditional companies, such as Mensor. On my first day, we met with Jason Otto, President of Mensor. He told me that he has been with the company for more than two decades, starting as an engineer, before moving up the management chain as product manager, director of sales, and other positions before becoming President.

He said, “Mensor was started in Houston in 1968 by Jerry Fruit and a small group of engineers from Texas Instruments. Jerry had an idea for designing and manufacturing precision pressure measuring and pressure calibration instruments and systems. The company shipped their first product, a quartz manometer for the aerospace industry, in 1970 and most of the company’s business was government contracts.

The company relocated to San Marcos in 1978, but in 1981, our building caught fire and burned to the ground. The company kept going with the help of vendors and customers while a new 26,000 sq. ft. building was built on the same site in only five months.  The employees kept their jobs by actually working to help build the new building.

Otto explained, “We acquired our control line of products from Texas Instruments and introduced new controller products in 1983, 1992, and 1997. We introduced a Quartz Pressure Calibrator in 2001, and the modern CPC6000 Automated Pressure Calibrator in 2004.

In 2006, we were acquired by WIKA Alexander Wiegand SE & Co. KG, a very large privately held company in Germany, with a U. S. facility in Lawrenceville, Ga. It was time for the owners of the company to “cash out,” and it was a smooth transition.

Our core competency is pressure sensor accuracy, and it is a very niche market.  It is tricky to hire talent, so we have to hire from competitors, as well as engineering graduates.  Texas State University, Texas A &M, and the University of Texas in San Antonio and Austin have provided many of our new engineers.  We also need calibration lab technicians, people skilled in technical assembly, as well as machinists for our in-house machine shop. We haven’t had any trouble hiring machinists.

I asked if the company has been through training in Lean Six Sigma, and he said, “Our Lean training started after our acquisition by WIKA. We currently have two Lean Six Sigma Black Belts, who do about 6 -8 kaizen events per year.  We practice 5S and use QCSD boards for visual management of teams. We put together cross functional teams, use cellular assembly, and have a vendor qualification program. We have never outsourced any of our manufacturing overseas, but we have customers in China and Malaysia. We use the WIKA global sales team, but use manufacturers reps to sell into Mexico and the maquilas because it is a long sales cycle. WIKA has 48 locations around the world, and as part of the WIKA Calibration Line, we represent about 6 percent of the company’s business.”

Next, we met with John Malik, General Manager of Altra Couplings in San Marcos. Malik said, “I grew up working in my dad’s auto parts store. I have been with the company since I graduated with an engineering degree and have survived three sets of company owners.  The company was started in Houston and moved to San Marcos in the early 1980s. We were sold to TH Woods in 1990, and then sold to ATR Inc. in 2007, whose corporate headquarters is located in Santa Ana, Calif. ATR has 28 plants and production facilities around the world, with seven locations in the U. S. We have about 120 employees currently.”

Malik explained, “We are a leading global designer, producer and marketer of a wide range of mechanical power transmission components. Our products control and transmit power and torque in virtually any industrial application involving movement and are sold in more than 70 countries worldwide in industries including: energy, general industrial, material handling, metals, mining, specialty machinery, transportation, and turf and garden. Our portfolio of products includes clutches, brakes, couplings, as well as gearing and power transmission components. However, we don’t do any high-volume couplings for the automotive industry.

When I asked about Lean, he said, “We have a team of company employees who have helped us become lean, and the productive gains are essential. It really comes down to asset utilization of people assets and capital assets.  You want to keep them adding value continuously. The approach we have taken is a value stream approach to our products. We go narrow and deep in an area and develop it, and then move on to another area.”

Malik added, “We have even implemented Lean Accounting.  I spent a lot of time with engineers to understand the true costs. We have some good decision rules for the “make or buy” decision process.  Our biggest promoter is our CFO, but our Lean program goes all the way to the top.”

I asked what Altra’s biggest problem is, and Malik responded, “Finding new employees. This is an area that doesn’t have a long tradition in manufacturing. People don’t know what manufacturing looks like, and the mind set for years has been getting a college degree rather than vocational training.   There are never enough trained applicants, so we train our own workers. We now have second and third generation workers. It is a lot about how we treat people and the opportunities for growth.”

He added, “We make all our own castings in our Erie, Penn. plant and buy the forgings we need.  We have three manufacturing facilities in the U.S. and have a plant in the U.K. We bought a company in Germany and have a plant in China.  That plant makes some parts for us, and we make some parts for them.  We also have a small facility in Brazil in order to have local content and avoid the high tariffs.”

On my last day in San Marcos, we visited CFAN, which was formed in 1993, as a 50/50 Joint Venture between GE Aviation and Saffron (SNECMA) of France. The partnership was created to introduce composite fan blades in a GE90 engine that powers the Boeing 777.  CFAN has leveraged the success of this product to introduce additional fan blades on the GEnx engines that power the Boeing 787 and Boeing 747-8.

We met with Mo Mattocks, who is the President and Plant Manager for CFAN. He is responsible for all plant operations including over 500 employees executing product delivery, quality, and productivity, as well as plant financial results and personnel safety. Mattocks said, “I am originally from New York, but graduated for the University of Michigan and Georgia Tech. I have worked for GE for 21 years and previously worked at the GE Aviation in Kansas City and Atlanta.”

He explained, ”CFAN successfully transferred the composite fan blade manufacturing process from the laboratory to the shop floor and delivered the first production GE90-94B fan blade in September 1994.  At first, our quality level was only about 80 percent, so there were a lot of rejects. We kept improving our processes using the widely recognized Six-Sigma methodology, focusing on eliminating defects and reducing variation in shop floor. Over the years, we kept improving our processes, so that our scrap rate is down to only about 1 percent.

In 2001, we started production of the composite fan blade for the GE90-115B growth engine. The GEnx1B fan blade was introduced to production in 2005 and the GEnx2B in 2007. In 2016, we started to make fan blades for the GE9nx, which had its first test flight last week. We are an approved FAA repair station for the GE90 and GEnx fan blades fan.  We have doubled our volume since 2009 and have produced more than 20,000 composite fan blades at our plant. We produce about 165 fan blades per week, and each fan blade takes about 340 hours. We expanded the plant from 160,000 sq. ft. to 275,000 sq. ft., and the whole plant is temperature controlled to keep the composite material from “curing” on hot days.”

I told Mr. Mattocks that in the past, I sold composite parts as a sales rep for a company located in Post Falls, Idaho so am familiar with the painstaking production methods used for pre-preg layup composite parts. When we walked the plant floor to see the whole production cycle from start to finish, I could see how meticulous the hand layup process is for these very critically dimensioned fan blades. It would be too tedious to describe the whole production process from start-to-finish, but the number of steps it takes to produce a finished fan blade was mind-boggling.

My last stop before leaving the San Marcos region to spend the weekend with my nephew and his family at their nearby ranch was to RSI Inc., located in Kyle, Texas. We met with President Harish Malkani, who founded the company in 1983. Malkani is originally from India where he earned a B.S. (Chemistry) from the University of Poona. He also received a degree in Chemical Engineering from the University of California at Berkeley and a Graduate Degree in Marketing from the University of California at Berkeley. He was employed with Ray Chem Corp. from 1969 to 1983.

While RSI’s website describes the company as distributor stocking and supplying standard mil-spec products including, but not limited to high-speed interconnect solutions and a wide range of electro-mechanical components, Malkani said, “I started the company as a distributor but over the years we became a value-added manufacturer. I can’t tell you about all of the defense and military programs for which we have used our expertise to provide solutions to the government and defense contractors because they were classified programs. We specialize in providing RFI/EMI solutions. We have done work for BAE, Lockheed, Raytheon, Aerojet, and other Department of Defense prime contractors.  We are a Silver certified supplier for Boeing. We also do work for companies in the energy, industrial, transportation, and the oil and gas industries.”

When we toured the shop floor, I could see that the company has the manufacturing, assembly, and test equipment to produce custom assemblies and systems for a variety of applications.

Malkani noted, “Our biggest problem is getting qualified workers.  I have hired from Texas State University, but I need more help in finding people with technical skills who are not engineers.  We are going to train some teachers at the local high school in our technology.”

He was assured by Dr. Cara DiMattina-Ryan, Director of Existing Business & Workforce Development at the Greater San Marcos Partnership (GSMP) that they would help him get connected to the local programs at the Austin Community College’s local Hays Campus.

Since finding technical skilled workers is critical to all of the companies I visited, I was happy that my hosts arranged for me to have lunch the first day with Dr. Hector Aguilar, who is the Executive Dean of Austin Community College’s Continuing Education division. He said, “Maintaining a talented and productive workforce in a growing local economy requires a commitment to employee development. ACC meets the training needs of businesses by partnering with them to tailor a custom learning curriculum that can be delivered on-site to employees. We have seven campuses in the western Austin region and have about 60,000 students enrolled.  Each community college in the Texas system specializes in training for the types of industries in their area. Houston specializes in oil and gas. Austin specializes in semiconductor, aeronautical, and sensor industries, and San Antonio specializes in training for automotive. “

He explained, “The Texas Workforce Commission is responsible for helping companies get training for their employees, and Texas pays for the training. Samsung was the first large manufacturing company for which we provided training when they came to the region. They received a grant of $3 million for the training. Samsung came up with 12 techniques to be taught in an around the clock program under a three-year program (24-hours a day, seven days a week).  The original 12 topics became 63 topics, and we trained 1,530 employees in the three years. We had to hire specialists in industries and then cross-train each one so they could teach multiple topics. We did a pre-test and post-test for students. The average pre-test score is 20 percent, and the average post-test score is 85 percent.

He added, “Under our Workforce Solutions Rural Capital Area, training for future employees is provided for free.  For example, when EPIC Piping bought an existing facility in San Marcos in 2014, they needed to hire new employees. They do specialized welding of pipes. GSMP came to us to help set up training for new employees.”

I was informed by Ashley Gossen, Vice President of Marketing & Communications for GSMP that underemployment is high in the region – a selling point for companies looking for talent. She said that the greater San Marcos region has more than 5,400 workers with bachelor or graduate degrees working in jobs that don’t require them.

It is obvious that the San Marcos region has a great deal to offer startup, existing, and transplant manufacturers: a good business climate, low taxes, skilled workers, and the educational facilities and programs to train new workers.

 

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California Economic Summit Sets Goals to Elevate California

Wednesday, January 24th, 2018

The sixth annual California Economic Summit was held on November 2nd – 3rd in San Diego.  The Summit was convened by CA Fwd and the California Stewardship Network, with a long-list of sponsors and partners. More than 500 civic, business, attended the event held at the Hilton San Diego Bayfront.  The theme of the Summit was Elevate California with the goal of achieving:

  • One million more skilled workers
  • One million more homes
  • One million more acre-feet of water

The statewide gathering highlighted higher education as an important component to a new initiative to restore upward mobility in the state. I was only able to attend day two, which began with a welcome by Mark Cafferty, President of the San Diego Regional Economic Development Corporation, and San Diego County Supervisor Greg Cox. Mr. Cafferty said, “California’s brand around the world is remarkable.  We need to prepare and support our most important assets – people. We need to help Californians live in sustainable communities, and we need to create one million more middle class jobs to ‘future proof’ California for Californians.”

Supervisor Cox said, “We now have 1,400 “Blue tech” companies representing 46,000 employees and making a $14 billion contribution to our economic, creating blue collar and white-collar jobs.” He mentioned that according to the recent report, the impact of the military represents 22% of the region’s jobs.

The day started with a panel of millennial and Next Gen leaders discussing their perspective on how California’s economy and the high cost of living are affecting them and their peers. Christine Werstler was the panel leader, and the panelists were:  Assemblywomen Autumn Burke, Sean Bhardwaj, founder and CEO of Aspire 3, and Laura Clark of YIMBY Action. They shared that the major challenges are:  affordable housing, access to fundamental services like health care and education, rapid change, and an unknown future.

Assemblywoman Burke said, “You can only do so much with legislation. We need to provide resources. It’s important to know that we have a college system that doesn’t have room for everybody, even if they qualify, Access to education should be a high priority.” Burke added that many of those are students from disenfranchised communities. Burke said, “We have the data, and now we need to put it into action and work with private industry to provide the opportunities and resources. It is our job as legislators to provide all of the things they need. “

Panelist Sean Bhardwaj said, “We need to teach entrepreneurism as a skill across disciplines in colleges and universities so they are prepared to find and create their career opportunities for the future. Only 19% of millennials see other people as trustworthy, 10% lower than other generations. They need to build personal relationships or they will not engage.

Bhardwaj added, “Each and every one of us has a talent and a skill that we can bring to the world. We need to break out of the thinking of what we link learning is and think what it could be. Technology is a tool to make resources more accessible.  We need to look at what are the tools we can provide so we can use the tools quickly We need to figure out what are the skills needed today and quickly provide the opportunities to learn them.”

Clark said, “Millennials are angry – 20% are living in poverty, and we need to bring them up. It is important to have clustering of industries in regions to provide career advancement.” She urged institutions to make sure college students are registered to vote so they have a voice on issues including funding.

The next panel featured leaders from all three of the state’s public higher education systems: University of California President Janet Napolitano, California State University Chancellor Timothy White and California Community Colleges Chancellor Eloy Ortiz Oakley. Ryan Smith was the panel leader.

“When we think about income inequality in our country and California, the single tried and true tactic that has worked over time has been access to higher education in terms of increasing social mobility,” said Napolitano. “When I remind people that 45 percent of the entering class at University of California are first-generation college students, that’s real opportunity that public higher education presents in California. In the UC system, we have increased enrollment by 10% in the last two years.”

When asked about affordability, the leaders emphasized the widespread use of financial aid to cut tuition and fees, but reminded the audience that the total cost of education also includes California’s high housing costs and other expenses.

Chancellor White said, “There is a capacity problem. We turn away about 30,000 students every year. We need to build more capacity.  If we don’t make this investment, it will be a higher cost in the future if we don’t succeed.”

Ortiz Oakley said, “We are in 114 communities and we need to design for the future jobs, so we looking at what are the job needs of different regions to create upward mobility and train more skilled workers needed across the state. We’ve spent a lot of time and fortunately we’ve had the investment over the last several years through the Strong Workforce to take a hard look at the regions of California to begin preparing ourselves to develop curricula for the jobs of today and the future, not the jobs of yesterday.”

All three of the Democrat gubernatorial candidates appeared at the Summit.  I missed the appearance of Lt. Governor Gavin Newsom the first day, but day two, former Los Angeles Mayor Antonio Villaraigosa and State Treasurer John Chiang were interviewed. Villagorosa said, “If it were a country, California would rank sixth in the world economies, but we rank down with Romania in the level of poverty.”  He agreed with Assemblywoman Burke. “If we’re going to survive and thrive, we’re going to have to do a better job at growing middle class jobs,” adding that 60 percent of high school kids are Latino and African American, but only 13 percent go on to a four-year college. He said, “We’ve got to address that. We’ll be a million and half down in college graduates by 2025 and a million down in people with specialized skills.”

Chiang said, “We have to understand that we ought to celebrate the diversity of our resources. It’s all about the people and I believe we have an area that is the magnet that draws people. It’s the idea of what California is, so we can flourish uniquely because of the extraordinary diversity that we have.”

“The 2017 Summit sought to advance these ambitious themes during the event and in the coming year:

  • Create a unifying triple-bottom-line vision for increasing economic security and upward mobility
  • Expand the strength and diversity of the Summit network to increase its influence on state and local policy decisions
  • Mature the Summit as a formal civic partner with government to advance triple-bottom-line policies:

While I applaud the goals of the Summit co-conveners and partners, I wonder why no one seemed to connect the fact that our losing 33% (618,000) of our higher-paying manufacturing jobs from the year 2000 -2010 might be a major cause of our increased rate of poverty.

According to data from the California Manufacturing Technology Association, we have only regained about 50,000 manufacturing jobs since then.  As shown by the following chart from CMTA Champions of Manufacturing blog by V.P. Gino diCaro, California is lagging behind the rest of the country in regaining manufacturing jobs, and California only attracted 1.6% of reshored jobs from 2013 – 2016.

I also fail to see how we can achieve the goal one million more skilled workers without addressing California’s adverse business climate that is driving manufacturing companies to leave California. Not one speaker even mentioned the topic of California’s business climate.

For 20 years, the Small Business & Entrepreneurship Council has published a report, titled the Small Business Policy Index, by their Chief Economist, Raymond J. Keating, which ranks the states on policy measures and costs impacting entrepreneurship and small business growth. According to the 2016 report, California ranks dead last, and has been dead last for several years. The report “ties together 50 major government-imposed or government-related costs impacting small businesses and entrepreneurs across a broad spectrum of industries and types of businesses, which include: corporate and personal income tax rates, individual and corporate capital gains taxes, property taxes, sales, growth receipts, and excise taxes, death taxes, unemployment tax rates, gas and diesel tax rates, Workers’ Compensation premium costs, energy regulation, State minimum wage, paid family leave, etc.  It even ranks states by the number of government employees, Per Capita State and Local Government Spending, Per Capita State and Local Government Debt, and various categories of lawsuit reform.

A brief look at how California ranks reveals:

  • California has the highest personal income tax rate and individual capital gains tax at 13.3%
  • California ranks 50th in Workers Compensation premiums cost at 3.48
  • California ranks 49th in energy regulatory costs
  • California ranks 43rd in corporate income taxes and 44th in corporate capital gains tax at 8.84%

On the plus side, California ranks first in the lowest unemployment taxes at the low rate of 0.81. Thanks to Proposition 13 still being in effect, California only ranks 22nd in property taxes at 2.835%. In 2016, California only ranked 46th in gas taxes at 0.409 cents per gallon, but would rank 49th now after raising its gas taxes by 12 cents per gallon the week after the Summit.

As long as California’s legislators and other leaders have their “head in the sand,” nothing will be done about improving the business climate of California. I challenge the State legislature to do their job as legislators to provide all of the things business needs to grow and expand employment.

At the conclusion of the Summit, Oscar Chavez, assistant director at the Sonoma County Department of Human Services, announced that Sonoma County will be the site of the 2018 California Economic Summit. He said, “You cannot sit on the sidelines. This state needs you.” I would say, “This state needs leaders who address the issues affecting manufacturing if we want to achieve the lofty goals of the Summit.

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North Carolina Prepares for the Future through Training and Redevelopment

Tuesday, November 14th, 2017

At the TEDx San Diego event on Saturday, October 14th, Dr. Mary Walshok, Associate Vice Chancellor for Public Programs and Dean of Extension at the University of California, San Diego, gave a short talk in which she said we need to add HEART to STEM.  She coined the acronym HEART meaning Hands-on, Engaged, Applied, Relevant Training whereas STEM means Science, Technology, Engineering & Math.

She said too many educators don’t realize the need for the hands-on workers, such as machinists, welders, plumbers, electricians, etc. Too many parents are focused on their children getting a college education, which is why we have millions of unfilled jobs requiring hands-on training. She recommended combining HEART and STEM to be more competitive as a country in the global economy.

Fortunately, there are more and more cities, regions, and states that have awakened to this problem and are doing something about it.  Charleston, South Carolina and the Piedmont Triad region of North Carolina are among the problem-solving regions.

After visiting the Guilford Technical Community College aviation training center that I wrote about in my last article, my hosts took me to visit one of the companies involved in the apprenticeship program, Machine Specialties Inc., where we met with Rob and Tammy Simmons, President and Executive Vice President of the company.

Rob said, “The company was founded by Carlos Black in 1969 after he moved to the U.S. from Argentina where he had apprenticed as a machinist. I started in 1980, and we were primarily a small machine shop supporting the textile industry. In 1990, we expanded into screw machine parts. We got our first government contract in 1995. I became part owner in 1998, and we moved into a new building in 2003. We expanded into doing large parts like aircraft landing gear and added in-house anodizing and chem film. We bought this building in 2009 with all of office equipment. We added a large laser cutting machine in 2009, and now have two lasers. Then, we bought two large multi axis WFL machines to be able to machine Titanium. We are open 24/7, but our weekend shift works three days. We are AS9100 Certified for aerospace, ISO 9001 for commercial, and ISO 13485 for medical parts.

I bought the company in 2005, and today, we are a leading contract machining and metal finishing specialist that designs and manufactures parts for many different industries including the aerospace, military, and medical industry. We plan to grow to be a $50 million-dollar company by 2020.”

He added, “We realized that we had a problem because about 15% of our employees will be old enough to retire within the next five years. So, we need to train new workers to take their place.”

Tammy said, “We were one of the first six companies to work with Guilford County Schools in starting a new apprenticeship program in the fall of 2016 for those interested in the advanced manufacturing field. Students will undergo a three to four-year program where they can receive an associate’s degree in Manufacturing Technology, a journeymen certificate as a machinist or welder, have their school paid for, and then end up with a manufacturing job.

About 50 students, juniors and seniors, applied for the program, and 27 students were selected to start the program initially.  This year we are up to 20 companies participating in the apprenticeship program.  During the summer, the students took classes for six weeks and then worked full-time for six weeks.

The students who are seniors when they start the program, spend half the day at school and then the other half working at our company. The students who applied as seniors and then graduate, go to school one day a week at GTCC to pursue their associate’s degree in manufacturing technology and then spend four days working.  GAP pays students hourly wage while on the job and when they sit in class at community college. I think it’s important to note that apprentices are paid while they are in class earning their degree because I don’t know of any other programs that do this. We also pay the students for their tuition and books while at GTCC.”

Afterward, Vice President Bob Schumacher gave us a tour of the plant, where we met three of their apprentices, two young men and one young woman.  One of the young men had graduated from high school before starting the program in the summer, and two are seniors this year. The young woman knew she wanted to be a welder when she started the program because her family have been employed in the manufacturing industry.

Then, we drove to Browns Summit, near Greensboro, to visit ABCO Automation, where we met with Brad Kemmerer, President   and CEO, and Jack Walsh, EVP Sales and Marketing.  Mr. Kemmerer said, “We build custom automation equipment and are a FANUC and KUKA robot integrator. Our company was started in 1977 by Graham Ricks, but we converted to an ESOP (Employee Stock Ownership Plan) in 1998. We started working with Coca Cola in the beginning to build electrical control systems and custom packaging equipment.  We designed the system that McDonalds uses to pump the syrup into their restaurants.

He explained, “In the late 1980s, we began to diversify our customer base by building custom equipment for a broader range of manufacturers. We began to go beyond packaging projects into manufacturing assembly, material handling, and inspection equipment. Now, our customer base is very diversified — all of the typical industries represented in North Carolina — Aerospace, Automotive, Chemical, Food & Beverage, Electronics, Healthcare, Pharmaceutical, Tobacco. Most of our customers have 25-30 plants around the world, and the average price of a system is $1 million.”

He added, “We have 150 employees, but added 23 employees in the last six months and 40 in the last 18 months.  We need to build a supply of future workers if we want to continue to grow. We have supported the robotics competition, For Inspiration & Recognition of Science & Technology (FIRST). For two weekends in January, we host more than 60 students from six local high school robotics teams to help them kick-start their FIRST Robotics Competition. After learning the theme of the competition, each team has just six weeks to design, build, and ship the robot to the FIRST national competition. We provide guidance from our mechanical engineers, electrical engineers, and project managers to assist students, their mentors, and coaches.

When we heard about the Guilford Apprenticeship Partners (GAP) program, we hosted the meetings and helped with the high schools. We currently have four apprentice students learning the skills of an electrician, mechanic, fabricator, and machinist. Two are first year apprentices and two are second year apprentices. We believe this a win-win for all—we supplement our current manufacturing team, and the students gain paid on the job experience while earning a college education.”

By this time, it was late afternoon, so we headed back to Greensboro to enjoy dinner at Natty Green’s Kitchen + Market, which is a combination micro-brewery, farm-to-market restaurant, and store located in a redeveloped textile mill.  Natty Green’s is in one of the buildings of Revolution Mill, a 45-acre historic textile campus that brings apartments, restaurants, events, history, and innovation together as the “Place of Choice to Live, Work and Create in Greensboro.”

Nick Piornack, Business Development Manager, gave us a tour of two of the former textile mill buildings — one that has been re-purposed for offices and studio space, and the other as an apartment building.  Between two of the apartment building is an outside event space where one of the finalists of The Voice was performing.  There is one classic building yet to be redeveloped on the property.

From the website, I learned that Revolution Mill is “a historic textile mill campus encompassing the Revolution Mill and Olympic Mill sites, with adjacent land connected by North Buffalo Creek. Located just north of downtown Greensboro, Revolution began operations as the South’s first large flannel mill in 1899 and for decades anchored a thriving community of workers and craftspeople. The facility included over 640,000 feet of working space before the textile industry decline led to its closure in 1982. For the next few decades, limited sections of Revolution were renovated into office space, while other parts of the property fell into disuse and disrepair. In 2012 Self-Help assumed ownership of Revolution Mill and is completing the property’s transformation into a mixed-use development…Self-Help is a development credit union and lender headquartered in Durham, NC.”

After the tour, we met with co-founder, Kayne Fisher, of Natty Green’s Kitchen + Market, who gave us a behind the scene tour of the restaurant. Mr. Fisher told us that he had dreamed of owning his own chop house and neighborhood market since childhood. So, when the opportunity to open a restaurant in the Carpenter’s Shop at Revolution Mill came around, his brain-child came to life. The market included a butcher’s counter where you could buy cuts of meat the restaurant used in its menu. As a non-beer drinker, I actually enjoyed tasting a beer that had chocolate in it. Besides the usual steak, chicken, hamburgers, and salads, the menu offered pork chops, lamb chops, and braised brisket, the latter being my choice. All of our diners were delicious.

At the end of a very fully day, it felt good to have seen the results of the redevelopment of an important industrial region with new industries, the re-purposing of old textile plants, and the creation of an apprenticeship program to foster the development of the next generation of manufacturing workers.

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