OJT Process - Eclipse Training...

Mill B Sorter On-Job Training Process Others set their standards by what you do every day!

Revised 06/2018 Cottage Grove

OJT Process

Who is required to complete this packet: New to this position Cross Training

Staying Qualified on a Job: Team Member must

o enter time for job performed when working (enter task profile ID)

o and inform their Team Leader Role and Responsibility

Team Leader: Following through with each employee

Trainer: Ensure OJT checklist requirements are met

OJT Facilitator: Recordkeeping and facilitating information

Safety Steward: Cover all aspects of training on Safety Steward Guidelines

Learn and use Safe Start methods to ensure your safety



Team Leader & Trainer Expectations

Team leader: Be a partner with the trainer. Discuss the job and training aspects with trainer BEFORE the trainee arrives:

o Make sure that trainer understands the OJT and the Intrac module. o Review their expectations with them.

Talk about some of the more difficult parts of the job: o What are some common and uncommon upset conditions?

Talk about some of the misconceptions that people have about the job: o For instance, the difference between learning a job and becoming an expert at your job. o Let the trainer know how important the training is…for safety, for production, for

Cottage Grove. “If it’s worth doing it’s worth doing right.” Let trainer know that the team leader will be talking with them throughout the training:

o To see what the trainer thinks is going well. o Where the trainee might need help. o DO NOT hurry the process. o What ideas do you have that would help the next trainer?

Let the trainer know how important their contribution is to the team and that they are part of the success of Cottage Grove.

While training, review the checklist and the trainer’s notes: o What is missing from the packet? o What is not current? o There should be ample notes in the completed checklist to show a true evaluation of the

training process. Trainer:

Read through the process before training begins. Talk with the team leader and safety steward about concerns that may come up during training. If trainer is not sure the trainee is ready, talk with the team leader about this. Give the trainee the necessary time to learn the job – no rush. Realize not everyone is the “greatest” right off the bat. You can be a good operator in a couple

of weeks, but it takes time to be a great operator. No exceptions. Be patient. All areas of the OJT must be reviewed and completed with the trainee. Read all the pages…make notes as you go through the process.

Stress the importance of knowing your up and down stream customers – how you can work with them for the benefit of all.



Mill B – Job Expectations and Job Scope

Expectations:

Perform your job in a safe, conscientious manner abiding by all company policies and procedures.

Attendance – be on the job when whistle blows with proper PPE.

Breaks are taken within the handyperson’s schedule.

Keep your cab and work area clean.

Make sure all tools are sharp and stored properly. Notify handyperson when need for replacement.

Train other operators as required and keep up with all training – Intrac, JSAs.

Communicate any operational events that may affect safety or production to appropriate persons including other shifts.

Teamwork – working and communicating well with others. Treat others with dignity and respect and paying attention to up-stream and down-stream customers.

Qualified operators must maintain the required production levels. Sorter Operator:

Maintain a continuous flow of lumber from the Trimmer to the bins. Drop loads of lumber on to transfer chains for the Stacker. Work and move safely on the Sorter walkways. Keep loads on the transfer chains neat and separated. Anticipate which loads to drop. Keep all tools stowed in proper receptacles. Make sure all C-hooks are in place and functional. Be able to enable/disable C-hooks. Advise Stacker Operator of any foreseeable problems with loads. This is not a definitive list of all required duties.

Trainee Date Team Leader Date For Employee’s File



3 Tier Training Plan –

Trainer

Trainee

Team Leader

• Tier One –

Trainee reviews OJT, completes special training for job, Intrac training, memorize machine center components, learn LOTOT for job.

Trainee observes trainer doing job

Complete blank machine center maps to demonstrate component knowledge

Initials

Initials

Initials

• Tier Two –

Trainee safely performs job tasks for short periods of time

Initials

Initials

Initials

• Tier Three –

Trainer can leave trainee for short periods o Trainer must have radio or be close by o Trainer cannot be performing a different job – they attention

must be with the trainee

Trainee safely performs job tasks for at production levels.

Initials

Initials

Initials

Before beginning each new Tier: Team Leader, Trainer and Trainee will discuss expectations and initial appropriate column. NOTE: Red Hats are required to partner with another person when locking out during their 60 Day period.



Qualification Checklist

Trainee Name: Blank Maps Completed: Date Training Started: Date Qualified: Trainer Signature: 2nd Trainer Signature: Safety Steward Signature: Purpose of Training:

Bid Job Cross Training Date completed: Date completed: Pinkpak/CG Seniority / Intrac Completed 2X

ESC Safety Intrac current

All Safety and OJT requirements for this job have been successfully completed.

Teamleader: Date

Operations Manager: Date:

OJT Facilitator:

Safety Intrac Modules up to date

Machine Center Module completed X2 & Checklist entered into Intrac

CG Seniority Map



On-Job Training -– 120 hours minimum training time required Intrac Training / Specialized Training – First Week � All Safety Intrac Modules must be up to date Machine Center Intrac Module must be completed

before moving to next step. Specialized training must be completed now:

� Review RADAR+ What does it stand for? How do I use it? Training

�LOTOT Training at MCC locations (Demonstrate area & task specific lockouts for job center) � Blank component maps - Learn component names – be able to fill-in blank maps

Begin machine center job training.

� Begin On-Job Checklist – Mark corrections for needed updates/changes. Job Training (Second & Third Weeks of Job Training)

� Additional training 1 week minimum with 2nd full time operator (prefer on another shift)

� Work with Up & Down Stream Customers – minimum of 4 hour each Drop/Trimmer Signature: Stacker Signature:

� Complete Intrac job training module for the second time. � Please note any corrections that need to be made to the Intrac Module and give notes to OJT

Facilitator with your checklist packet.



Learn more about the Job Area Trades People OJT with Operator –

Mechanical Electrical

• Walk the flow of material from infeed to out feed. Explain devices.

• Communicate past mechanical/electrical/filing downtime events

• Discuss routine maintenance schedules and why.

• Discussion of areas that the operator can assist trades people.

• Develop a plan for relaying critical information/questions to route owner.

• Shift schedule of route owners

• What information needs to be communicated to engineering when using a radio for a reliability event?

• Walk through of LOTOT for area.

• Hot Works Expectations.

N/A

• Downtime expectations (if machine is down during shift what information will trades people need?)

Route Owner Mechanical: Route Owner Electrical:



Final Check Off Trainer, Team Leader, Safety Steward and OJT Facilitator confirm all requirements are met: Evaluate:

� Checklist have been completed

� Trainee describes the flow of the area

� Trainee demonstrates safety requirements

� Trainee demonstrates willingness to accept directions

� Comments/Concerns from engineering, trainers, Safety Stewards, Team Leader



Questions / Observations / Suggestions: ________________________________________________________________________________

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Feedback: ________________________________________________________________________________

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6/27/2018 Cottage Grove

On-Job Training Checklists

The following procedures will be demonstrated by your Trainer. When you have had time to practice, your Trainer will ask you to perform each item and will check you off. If you don't understand any item, ask the Trainer to repeat the demonstration or explanation. PPE

DEMO

CHECK

• Identify personal protective equipment required:

Hard hat

Safety boots

Hearing protection

Safety glasses

Disposable Respirator (Voluntary Use Form)

Goggles when using an air hose

Gloves – appropriate for the task

Chaps (when using a chainsaw)

Company radio

• Safe Start – These four states….:

Rushing

Frustration

Fatigue

Complacency

Can cause or contribute to these critical errors….

Eyes not on Task

Mind not on Task

Line-of-Fire

Balance/Traction/Grip

…which increase the risk of injury.



First Aid/Emergency Response/Environmental

DEMO

CHECK

• Identify location of the following:

First Aid kits

Bloodborne Pathogen kits

Eye wash stations

All Fire extinguishers, All Fire Alarms, Plant Evacuation Alarm

• Locate assembly areas:

Primary assembly area — mill b stacker / parking lot

Secondary assembly area — merch tower at ground level

• Identify appropriate emergency response for your area:

First Aid:

- Call a First Responder – know First Responders for your area and shift.

Imminent danger to you or others:

- Hit the EMERGENCY STOP button on operator console.

Help Needed Whistle:

- Safely shut down machine center and listen for instruction from the Teamleader.

Fire Alarm — Evacuation:

- Safely shut down machine center and evacuate to assembly area.

Plant Evacuation Alarm — Evacuation:

Call 9-911 as appropriate in any emergency.

• Identify spill response:

Ensure personal safety and the safety of those around you.

Contain and stop the leak if possible.

Call for help (your Team Leader and/or 2U).

Notify your Team Leader if you have not already done so.



First Aid/Emergency Response/Environmental (cont.)

DEMO

CHECK

• Locate SDS for materials you may be exposed to:

Access through 3E system electronically.

Hard copy available from Environmental Manager.

• Locate the satellite station for aerosol cans.

RADAR+

• Use RADAR+ Assessment process for any stop in the flow or process (upset condition):

What State am I in?

Complete RADAR+ form and leave on the RADAR+ clipboard (the Teamleader will pick these up throughout the week).

Identify potential hazards — if you check the Hazard ID box.

Turn in completed forms to your Team Leader.

Safe Work Practices

• Demonstrate safe lifting procedures

Beware of Complacency

Lift with your legs.

Maintain firm footing.

Keep your back straight.

Keep the load close to your body.

Watch for pinch points as you set down a load.

Ask for assistance as necessary. Dr Greg appointments can be used for on or off the job advice. Let your Team Leader know you would like an appointment.



Safe Work Practices- continued

DEMO

CHECK

• Demonstrate safe use of tools (e.g., picaroons and pike poles):

Eyes on Task & Mind on Task before using tools

Check tool condition before use — no cracked or broken handles, points sharp.

Replace worn or damaged tools.

Keep tool clear of obstructions (e.g., walls, handrails, consoles, wood boxes) while using it.

Ensure you can hold the entire weight of the tool while using it.

Maintain stance and balance while using a long pike pole.

• Demonstrate safe use of an air hose: Beware of Line of Fire -

Wear goggles (dust mask optional).

Ensure air nozzle has relief holes.

Maintain a firm grip on hose.

Keep hose clear of moving equipment.

Never use an air hose to clean off yourself or your clothing.

Never blow pressurized air towards others.

Heating and Cooling • Heaters:

Clean off to prevent eye irritation from blowing dust

Be aware of fire hazards (you’re generating a lot of heat)

Turn heaters and fans off at the end of shift

Kerosene heaters require a Hot Works Permit (see your Team Leader if you have questions)

• Fans:

Clean off to prevent eye irritation from blowing dust.



Lumber Handling – Eyes & Mind On Task

DEMO

CHECK

• Lugged and Flights chains Stop chains to reach in or use tool LOTOT to enter the bite

• Chains Stop chains to use a tool LOTOT to enter the bite

• Pinch points:

Between lumber, components and lumber, and components themselves.

Storage of Tools

DEMO CHECK

• Store tools in the designated holders when not in use. Talk to your team leader if you need tool holders

Picaroons and Pike Poles

• Picaroons and Pike Poles

Replace tools that are in poor condition

Locate tool crib for sharp & dull picaroons

Spikes must be sharp and handles have no sharp or jagged edges or spurs

• Do not rest a tool handle on an object such as wood box, handrails, operator consoles, etc while using.

• When tool is in use, you must be able to hold the entire weight of the tool as you are using it; this will prevent the tool from bouncing and striking the user

Proper stance – distribute your weight

Be aware of your surroundings

• Be aware of your lifting capabilities – the longer the pike pole the more awkward a position you may put yourself into



Identify Hazards and Safe Work Procedures DEMO

CHECK

What state are you in?

What critical errors can increase the risk of injury?

Use caution on all stairs and walkways: o Watch for debris build-ups

o Watch for wet or slippery areas

o Use three point contact at all times

• Watch for low overhead clearance areas when cleaning up:

Position yourself to avoid twisting your body

Ensure materials‚ i.e.‚ tools or waste receptacles are used or positioned safely

• Identify hazards near or under operating equipment:

Do not enter areas without following lock-out procedures



LOTOT

Rushing, Frustration, Fatigue and complacency can lead to Mind Not on Task

• Locate the LOTOT Procedures Notebook:

Review procedures.

• Locate the Machine Center Map:

Review to identify machine center components.

Review the process flow.

• Demonstrate how to safely isolate a lockout switch or device:

Visually verify that MCC buckets doors are secure; arrows on panel screws are facing away from bucket

Stand to one side of a bucket with your face turned away and pull handle with your hand.

Watch for pinch points when depressing air dump valves.

• Describe LOTOT procedures for unscheduled downtime during normal operational hours including pre-shift:

Minimum lockout includes the component you are working on/in, and any component directly up or downstream.

• Describe LOTOT procedures for scheduled downtime (shutdowns or “windows”):

o Full area lockout is required (see Notebook for procedure) for scheduled downtimes.

• Follow the LOTOT Program.

Review lockout for all procedures in the Stacker LOTOT book: o Do not train lockout procedures by memory



World Class Housekeeping

Take Pride in Your Workplace! Housekeeping – YOU HAVE TIME!

DEMO

CHECK

Your workstation o Empty trash

Drop off at nearest Trash box o Empty recycle

Nearest blue recycle bin o Remove all personal items at end of shift

Take home or into your locker

Refrigerator – this is a privilege o Keep refrigerator clean

Clean any spills (even if they are not yours) o remove all items at end of your work week o wipe down shelves o wipe down outside of refrigerator

Returnable Bottles o Bags can be taken to the millwright shop – to the right as you enter coming

from the mill or merch line FYI – Bottles are a large part of the ACTivity Club funding.

Operator Lockers o Keep lockers clean

Name plates on lockers o Do not store items on top of lockers o No “decorating” outside of locker – no stickers

Cabinets o Should be labeled o Items stored neatly inside o Limit items –

remove all unused items do not overstock

o No storage on top of cabinets



World Class Housekeeping

Take Pride in Your Workplace! Housekeeping – YOU HAVE TIME!

DEMO

CHECK

Tools should be stored in tool holders o No leaning against a wall or in a corner

Operator Station o Empty trash

Drop off at nearest Trash box o Empty recycle o Remove personal items at end of shift

Operator station o Clear desk – this is a work station for electricians

remove your items after every shift and as needed o Empty trash – as needed

Drop off at nearest Trash box o Empty recycle – as needed o Remove ALL personal items at end of shift

Returnable Bottles o Bags can be taken to the millwright shop – to the right as you enter through

the double doors FYI – Bottles are a large part of the ACTivity Club funding.

Operator Lockers o Keep lockers clean

Name plates on lockers Nothing on top of lockers No stickers or other debris on locker



Work Station Components and Controls

Components and Controls

DEMO

CHECK

• Identify location and function of the following components:

Speed-up lug chain

Sorter infeed speed-up chain

Sorter drive chain

J-hooks

Diverter arms

Diverter gate

Bins 1 - 37

Elevator

Dump Arms

Long range photo eyes:

- Bin lowering photo eyes

- Bin floor storage chain

- Floor chain sections 1 – 4

Re-entry rollcase

Incline chain

Unscrambler

J- Hook lock-out area

• Identify the function of the following controls and monitoring devices:

Main control console

Bin control panels

Sorter computer

Video monitors



Work Station Operation

Eyes on Task & Mind on Task before starting!! Perform Pre-start Checks and Start Up

DEMO

CHECK

• Make sure all guards are in place, gates closed and that no tools or other equipment have been left around the area.

• Check the area for personnel and equipment.

• Check condition of components:

Check for damaged C-hooks.

• Check contents of bins:

Plan lowering of full bins.

• Check computer for status of bins.

• Check hand tools:

Ensure tools are sharp and properly stored.

• Check for pinned bins:

Check before swing shift.

Check after Maintenance finishes working on the sorter.

Check after window cleanup done around floor chains.

• Clean photo eyes:

Lock out sorter drive to clean long range eyes.

Clean bin lowering eyes on full or disabled bins only.

• Check position of loads on floor chains:

Ensure boards are not crossed up.

• Check board for messages from other shift.



Perform Pre-start Checks and Start Up - cont

DEMO

CHECK

• Pickup all boards on ground and walkways

• Make sure # C hook in zone matches the # C hook disable screen

Start Up/Shut Down

DEMO

CHECK

• If sorter drive was locked out, inform Trimmer Operator when ready to start:

o Sorter drive is started at Trimmer’s console.

• Follow shut-down procedures:

o Ensure floor chains are off.

o Raise all empty bins.

• Use SORTER STOP when necessary to stop sorter drive in an emergency:

o Pull on same button to reset so Trimmer Operator can re-start when ready.

• Patrol catwalk continuously:

o Keep pieces straight in bins.

o Check that bins are receiving same size and length.

o Plan full bin lowering.

o Monitor quality of pieces.

o Watch for damaged J-hooks.

o Never reach into process without lotot

• Monitor bins for chimney stacking.

• Check status of bins on sorter computer monitor:

o Check status to ensure full bins are lowered quickly.

• Disable bins to prevent load from actively filling, while sorter is running:

o “Disable” at the monitor.

o After completing task, re-enable the bin at monitor.

• In order to dump partial loads while sorter is running:

o “Force Fill” the bin at monitor.

o Dump load as normal.



Monitor Bins (cont)

DEMO

CHECK

• Lower full bins when BIN FULL light is lit:

o Check position of other loads on floor chains:

- Use storage transfer when necessary.

o Ensure floor chains are running:

- Sometimes floor chains are stopped to dump loads.

o Turn the UP/DOWN switch to DOWN until it stops.

o Turn BIN ARM switch to DOWN.

o When bin is fully lowered, it will begin to empty onto chain.

o Wait until a quarter of the load is out onto chain, then turn BIN ARM switch to UP.

o When load is clear of forks, press the RESET switch to raise the bin.

o Bin will raise and reset.

o If bin does not reset, manually raise or lower bin to the limit switch and go through dumping process to reset bin – if this does not work, there may be a dirty eye or eyes might be out of line

• Watch bin as it lowers and comes back up:

o Check for hang-ups — stop bin if necessary.

o To stop bin, pull eye out of position. Replace eye to continue.

• When lowering bins for lock out:

o Wood should be dropped to within 3” of bottom on bin.

• Watch while dumping loads:

o Check for cross-ups or stuck boards:

- Do not press RESET button (with light); instead, use manual switch as it will clear the computer.

- Use the manual UP and DOWN switch to clear, then press the RESET button when ready to raise the bin.



Monitor Bins (cont.)

DEMO

CHECK

• Watch monitors for problems on the floor chains:

o Watch for pieces jamming in the chains.

o Watch for pieces crossing up on the chains.

o Watch for bins that open on their own.

o Watch for chains coming off sprocket:

- Call Maintenance for assistance if necessary.

• Respond to long range photo eye blockages:

o Check for piece sticking up blocking eyes.

o Tell Trimmer Operator when problem is cleared.

• Check for pieces jammed in the chains if sorter drive stops:

o Follow safe procedures to clear jammed piece.

o Look for chains off sprocket

Disable C-hooks (C-Hook does NOT need to be in the yellow zone to disable)

o Use computer monitor.

o Press ELECTRICIANS tab.

o Press C-HOOK DISABLE SCREEN button.

o Press the number of the C-Hook you want to disable. The number will appear in the box below.

o Press APPLY DISABLE TO C-HOOK # button.

o Disabled C-Hook number will turn red.

o Call Millwrights to repair C-hook and leave message on white board.

Re-enable C-hooks (location to re-enable C-hooks is between bins 35 & 36, between the square tubing between the bins, and is marked with a yellow paint line):

o Use main control console. o Just before repaired disabled hook comes into yellow designated area, turn

control to maint. This will stop sorter. o Now push Jog button until C-Hook is in the yellow designated area. The

yellow light will come on. o Press and hold C-hook lock-out button until the light goes out. o Verify on the monitor that the disabled number has turned from red to

green.



• Monitor bins for blocked or misaligned photo eye: o Bin will lower completely when not full. o Clean photo eye and reflector. o Call an Electrician if eye is knocked out of alignment.

• Storage Chain o Can be operated to run forward and stop o Must be manually run in reverse (stops after 3 seconds)

• Keep work area clean: o Pick up all boards from catwalk – trip hazard

Re-Entry

Coordinate with Stacker Operator and Mill B Outfeed driver to re-enter loads.

To bring in re-entry load: o Stop chain #4 o Lower Bin 37 arms o Make sure load is positioned correctly on re-entry, then raise the jump

rolls. o Run the load forward until correctly positioned on chain #4. o Lower jump rolls and run chain #4 forward

Sorter Overflows

Use the Sorter Stop button to clear sorter overflows.

Bin 37 – Lost Board Bin

Coordinate with Stacker Operator and Mill B Outfeed driver when this bin is ready to dump

“Force Fill” the bin at monitor.

o Dump load as normal.



Respond to Problems

RADAR+ – Sorter Bridging

Rushing, Frustration, Fatigue and complacency can lead to Mind Not on Task

DEMO

CHECK

• Should you experience bridging Call the Team Leader or PFC/Value Tech and together:

o Complete a RADAR+ Recognize the Risk Access the Situation DEVELOP A PLAN

Ask for Help as needed Act on your plan Report and Record



SAFETY STEWARD GUIDELINES �Who are your up and down stream customers? How can you affect them? �Tell me what specific PPE you are required to wear for this job? Why is it important? �RADAR+…When do you fill out one of these forms? Where are the forms? �Components section of OJT – show me where each of these components are located? �Where is the primary assembly? Secondary? What are a couple of routes to get there from here? �What are your responsibilities during an emergency? �Who are your shift Safety Stewards on this shift?…1st Responders? �Who are your Shop Stewards…Head Steward? Do you understand how they can help you? �Where are the closest First Aid boxes…Bloodborne Pathogen Kits? �Tell me about proper LOTOT… perform a mock area lock out together. You take the book and lead me through a mock lockout. �What are your safety questions? �If someone got hurt at this machine center what would be your guess about what happened? �What Safety recommendation do you have? Safety Steward – Initial here _________________ and sign on Qualification Page

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