Center of Excellence for Marine
Manufacturing & Technology
Skagit Valley College
DACUM Workshop Report
on
The Composite Technician
Olympic College
April 19, 2012
Agenda
Focus Questions:
“What is the expected work profile of a typical Composite Technologies Technician and what knowledge
skills and abilities will be required to do this work?”
8:30AM
Welcome from the President of Olympic College, Dr David Mitchell
Overview of Composite training at State Community and Technical colleges – Ann Avary,
Director of the Center ofExcellence for Marine Manufacturing & Technology at Skagit
Valley College
9:00AM
Introduction of the panel members – panel members
Introduction to the DACUM process and the agenda - Dave Cunningham
Workshop I
Mapping out the initial profile of the Composite Technologies Technician
Break
Finalizing the work profile
Noon
Lunch
Tour of the Composites Lab at Olympic College
1:15PM
Refinement of the Work profile and the component tasks
Identification of priorities
Break
Workshop II
Mapping out the necessary Knowledge Skills and Abilities required of Composites
Technology Technician (KSAs)
Break
Finalizing the KSAs
Wrap-up discussion
4:30PM
Adjourn
Participants:
1.
2.
3.
4.
5.
6.
7.
Tom Doughty, VP Administration, Janicki Industries
Doug Perry, CEO, Profile Composites
Brain Skelton, Production Manager, Profile Composites
Brian Nasralla, Industrial Engineering, The Boeing Company
Norman Nelson, Production Manager, Mervin Manufacturing
Preston Bosarge, Production Management, Ingalls Shipbuilding, Gulfport, Mississippi
Gary Coykendall, Program Research, Edmonds CC, National Resource Center for Material
Science
8. Dave Cunningham, - DACUM Facilitator, Cunningham Enterprises
Facilitation: Cunningham Enterprises; davidg.cunningham@comcast.net
2
Introductions:
Dr David Mitchell, President of Olympic welcomed the participants and thanked them for agreeing
to participate in this important process. Ann Avary, Director of the Marine Center of Excellence at
Skagit Valley College gave a brief overview of the whole project and the various Composite
Technology degree and certificate programs that are currently going on in the state. Represented on
the DACUM panel were representatives from several industries including aviation, marine, materials
research, and recreational products. Other industries where composite technology is gaining a
growing footprint in the state include medical prosthetics, wind energy and automotive.
After a brief discussion, the facilitator, Dave Cunningham, introduced the group to the DACUM
process and the agenda for the rest of the day. Following this, the workshop got underway with the
creation of the work profile of the Composite Technologies Technician. This process went through
the afternoon and ended at 4:30PM.
The preferred Attributes (Abilities) required of the Composite Technician:
Key Attributes
for working with composites
Physical capability to
work in a challenging
industrial setting
Has an analytical
approach to problem
solving
Has a strong work
ethic that includes
showing up on time,
every day.
Has a mechanical
aptitude and comfort
around power tools
and material handling
equipment.
Interested in learning
and personal
professional
development
Is knowledgeable
about and interested in
IT technologies
Willing to assume
responsibility
Is adaptable and
teachable
Has a passion for
polymer products
Values personal
hygiene and
appearance.
Is able to work
collaboratively in a
team
Communicates
effectively with others
Shows a history of being goal oriented
Facilitation: Cunningham Enterprises; davidg.cunningham@comcast.net
3
The Preferred Demonstrated Skill Sets required of the Composite Technician
Most critical and challenging skills
Accuracy and Attention
to Detail
A
Taking Directions
Team Participation
Communications
Physical Abilities
B
C
D
E
Complete the daily work on
schedule
Read, follow and comprehend
S.O.Ps
Has the ability to capture data and
report on it with accuracy
Mechanical aptitude
(good hand-eye coordination)
A1
Demonstrate efficient application
of all knowledge
B2
Follow work instructions and
MSDS
Play a constructive role as a
team member and support coworkers
C1
D1
Write clearly and effectively
A2
Able to take tests successfully
(professional development will be
ongoing)
A3
B2
Follow company philosophy
regards 5S and other LEAN
principles
B3
Follow the rules for working with
materials, chemicals and
equipment
B4
Able to learn about all the options
for using the correct tools for
specific tasks
B5
Act professionally and with
respect towards others
C2
E1
Demonstrate physical aptitude for
working in a production
environment
E2
Perform random testing and
sampling of product
A4
Inspect and differentiate
satisfactory and unsatisfactory
parts
A5
Anticipate outcomes of actions at
all times
A6
Facilitation: Cunningham Enterprises; davidg.cunningham@comcast.net
Work efficiently and
independently
C4
D2
Send, receive, store and retrieve
digital and other information on
computers
D3
Use the terminology of composite
technologies correctly
D4
Carry out repetitive tasks while
meeting high standards
E3
Handle and transport materials,
tools, equipment and chemicals
according to S.O.P.s
E4
Extract information from multiple
resources
D5
Extract information from graphs,
charts, specification sheets,
spreadsheets
D6
Extract technical information from
the internet
D7
4
The Recommended Knowledge Base for : Composite Technician (letters and numbers for ease of reference only)
= Most
Mechanical
Systems
A
important: * = Science, Technology, Engineering & Math
LEAN Manufacturing
Principles
B
STEM *
Handling Chemicals
and Compounds
D
Safety
Human Relations
E
F
Knowledge of basic
LEAN principles
(LEAN 101)
Basic Math and
Measurement
Knowledge of all
potential hazards in
handling chemicals
B1
C1
D1
Safety principles and all
prevailing safety
regulations including
OSHA and WISHA regs
E1
Knowledge of how to
actively listen to
guidance and
instructions
F1
A1
Knowledge of why
accuracy in the use of
tools and equipment is
pivotal to business
success
Knowledge of the S.O.P.s
for foreign object disposal
(FOD protocols)
Basic Chemistry
(compounds
formulation,
composites)
Knowledge of how
materials are identified
and the codes and
acronyms used
Knowledge of federal,
state and local
jurisdiction’s safety
requirements of the
company
Respect for diversity in
the workplace and an
understanding on why
this is important to a
business’s success
A2
B2
C2
D2
E2
F2
Knowledge of all
commonly used tools,
their limitations, dangers
and maintenance and
calibration frequencies
Knowledge of the
company policy around
LEAN manufacturing
principles
Knowledge of the
environmental impact of
production waste
Knowledge of
Ergonomics and its
applications in the design
of work cells & common
work practices
A3
B3
D3
E3
Knowledge of calibration
S.O.P.s for different tools
Knowledge of production
standards for regulatory
compliance & acceptability
B4
Know how to use
production and
maintenance tools
appropriately
A4
C
Basic GeoTolerancing
C3
Technical Terminology
(polymers and composite
creation)
C4
Basics on IT systems
Knowledge of proper
Knowledge of one’s own
and commonly used
disposable practices for
physical limits
applications
waste
C5
D4
E4
Technical
Knowledge of the whole
Knowledge of why
Comprehension
production environment
(priority on
standards are important to
and how all activities &
documentation)
the success of the business
processes interact
B5
C6
D5
Knowledge of the importance of all safety principles & SOPs as they apply to all aspects of work
Facilitation: Cunningham Enterprises; davidg.cunningham@comcast.net
5
The Work Profile of the typical Composite Technician
Main Duties
Primary Tasks: (Purple – most challenging tasks: Green – most commonly performed tasks; tan– both common and challenging)
Calculating resin geltimes & quantities
A1
Assembling
composite products
A3
Following the
laminate schedule
A5
Interpreting Blueprints
Curing composite
parts & products
Consistently meeting
schedule deadlines
A
A2
A4
A6
Checking
Documenting issues
and problems
Dealing with-out- of
tolerance & N.C.R.s
according to S.O.P.s
Sampling and taking
measurements
B
B1
B2
B3
Adopting ‘clean as
you go’ & shared
responsibility
practices
Maintaining tool
cleanliness according
to standards in
S.O.P.s
Complying with all
safety requirements
C1
C2
C3
Accurately cutting
materials
D1
Identifying &
differentiating
materials
D2
Tracking materials
(traceability)
D3
Observing inventory
protocols
D5
Avoiding wasted
motion
D4
Segregating
composite waste
D6
Writing QCLs at
Shift-changes
Working closely as a
team in a diverse
group
E2
Capturing lessons
learned and adjusting
S.O.P.s
E3
Cross train for work
in other departments
Pursue O.J.T. with
emphasis on learning
safety practices
Maintain personal
certification
Pursue certification
for A.C.M.A., and
A.B.Y.C.
Pursue certification
under OSHA and
EPA regulations
F1
F2
F3
F4
F5
The Production
Process
House Keeping
C
Material Handling
D
Communications
E
Training &
Professional
Development
F
E1
Facilitation: Cunningham Enterprises; davidg.cunningham@comcast.net
Operating Hand and
power-tools
A7
Operating
automated
machinery &
equipment
A8
Documenting
completed work
B4
Preventing damage
or debris
C4
Following work
instructions
C5
Maintaining
orientation of dry
materials
D7
Kitting materials
D8
Communicating
effectively with
customers (internal
& external)
E5
Following work
recipes
A9
Appropriately using a
range of measuring
devices
Monitoring &
checking machine
read-outs
A11
Mixing chemicals
Preparing and
inspecting molds
A13
A10
A12
Inspecting parts
Recording data
B5
B6
Maintaining consistent
standards in work
station
Minimizing waste
and maximizing
efficiency
C6
C7
Checking ‘out-life,’ of
materials
D9
Moving & storing
materials
D11
Handling composite
chemicals
D10
Controlling
inventory
D12
Using cutting
tools safely
D13
Handling tempsensitive bulk
materials
D14
Applying composite
terms correctly
Practice active
listening skills in all
interactions
E7
Monitor, track
and store
information
E8
E6
Packaging the
product
Trimming and
drilling composite
parts and products
A15
A14
Applying ‘plan,
do, check, act’
(PDCA) methods
in all processes
B7
Coordinating all
work with Quality
protocols and/or
the QC department
B8
Maintaining
cleanliness and
minimizing
contamination
C8
Tracking and
verifying
compliance to
MSDS
C9
Operating material
handling
equipment
D15
Arrange work-flow
& work station
according to
ergonomic principles
Guarding structural
integrity of product at
all times
C10
C11
Observing all safehandling protocols
D17
Establishing reorder points
D16
Maintain correct
labeling
D18
Act professionally
at all times
Respect and guard
company proprietary
information
E10
E9
Develop innovations
in product design, in
specs, in processes
and other business
categories
F6
6
Attending to lot #s
and product integrity
D19