How A ‘Touch Of Technology’ Can Invigorate the Training Experience

No matter how technologically advanced and intuitive today’s machines are, there remains one critical component that enables them to run effectively: the operator. Print operations worldwide spend a considerable amount of money to obtain the very best in pre- and postpress machinery so they can meet their clients’ continued demands. That’s why a dedicated commitment to employee training needs to be an integral part of that investment. What’s more, training programs that integrate digital components are likely to be more easily embraced—and assimilated—by today’s workers.

Case in Point: Webcrafters Inc.

In order to grow market share, Webcrafters, a family-owned, Wisconsin-based book manufacturing services company, recently installed Muller Martini’s Primera E140, a state-of-the-art saddle stitcher with runs at up to 14,000 cycles per hour. A comprehensive, effective training program was critical to meeting that objective. Webcrafters’ four-shift operation mandated that a total of eight employees (each with varying levels of experience) be trained: four primary operators, two engineers, and two maintenance workers.

With this particular installation, Muller Martini introduced a brand-new component to its training process: e-Learning. Studies have shown that e-learning can lead to increased retention and a stronger grasp of the subject at hand, primarily because the components (e.g., audio, video, interaction, etc.) work in tandem to reinforce the message. “The newer generation of people that are coming up are more in tuned with computers, the Internet, and electronic controls, and are more visually oriented. The multi-media component was a great enhancement to Muller’s overall training program, and our operators welcomed it,” noted Webcrafters Bindery Superintendent Kirby Frank.

The customized, multi-staged program Muller developed for Webcrafters consisted of:

1. Walk-through. Prior to any formal instruction, a Muller Martini trainer familiarized the trainees with the Primera, offering a basic overview from pocket through trimmer, including parts, processes and unique terminology, along with a general understanding of the machine’s mechanical, electrical and computer support.
2. E-learning. Following the walk-through, the group participated in an all-new, six to ten hour e-training session, conducted within a quiet classroom setting. Using a laptop computer that was projected onto a white board screen, the Muller Martini trainer helped facilitate a variety of electronic multimedia learning tools, that included PowerPoint presentations and video. Tests were administered following the completion of each e-module, and general group assessments were made in terms of what areas needed further reinforcement.
3. Classroom lecture. Continuing within a focused classroom environment, the Muller Martini trainer then reviewed and reinforced the lessons learned from the e-learning modules, and fielded any questions the trainees had. The group was also provided individual Primera Operator Manuals for further reference and note taking.
4. Hands-on. After the completion of classroom training, it was back to the plant floor and the Primera for some troubleshooting. Each operator was equipped with a headset, and the trainer utilized a wireless microphone so as not to disrupt surrounding co-workers. Better still, the wireless mike allowed for clear communication between the Muller Martini trainer and the class participants.
5. Follow-up. To round out the training process, the Muller Martini trainer returns for a follow-up visit at a later date to answer questions, observe production, assess needs, and make any additional recommendations that can further improve efficiencies. Because of the “on-demand” availability of the e-learning component, it remains available online for an additional six months to address turnover needs, or to simply allow already-trained staff to refresh particular skill-sets.

The combination of e-learning, traditional lecture, and hands-on machine training provided Webcrafters employees with the tools they needed to skillfully operate the Primera, while delivering a powerful end-to-end training experience. Elizabeth Mason, a Webcrafters’ employee who completed the Muller Martini training, observed: “The class training allowed us to be able to sit down with our books and multimedia materials and go through everything we learned that day and ask questions in a very comfortable, non-disruptive environment.”

Concluded Frank, “The whole process proceeded extremely well. When I came in the second day, and I saw the operators before their shift started, they were just extremely impressed with what they had gotten from just their first eight or so hours of training. And we hadn’t put a single piece of paper through the machine yet.”

Why is training so important?

• The printing industry is experiencing unprecedented turnover.
• There is a shortage of skilled labor.
• Technical colleges have eliminated apprenticeship programs.
• Companies that train and retain skilled employees will have a competitive advantage.

The Results Are in…

A truly successful training program delivers invaluable results on a variety of levels, specifically:

• Increased operational productivity, efficiency and predictability. A well-developed training program reduces the learning curve, thereby increasing productivity and efficiency. Machines run quicker and more effectively.
• Accelerated return on investment. Since the machine and products are up-and-running as soon as possible after installation, the duration for return on investment shortens, and profits are realized faster.
• Prolonged machine life. A good training program covers maintenance as well, further reducing downtime.
• Increased employee engagement. Effective, innovative training creates a highly positive workflow. It unleashes an energy and interest that has employees not only eager to participate, but allows them to grow into confident and professional operators.

At Muller Martini, training is a top priority, and tantamount to any lasting partnership with our clients. But when all is said and done, there is one unwavering component to any successful training program: commitment. Commitment by Muller Martini, our partners to their staff, and commitment by individual employees.

Dan Denue is vice president, Operations; and Fred Jones is national service manager, Muller Martini Inc.