Extrusion Operator Onboarding

Background

Georg Fischer Piping Systems is a global manufacturer of world-class piping products used across many industries and applications. Clients include Google, Meta, TSMC, and other big names that demand quality and reliability. 

Plastic piping is created through a process called extrusion, where melted plastic polymers are forced through a die (similiar to a mold) to create piping in different sizes and specifications. Extrusion Operators handle the setup and operation of the extruder, as well as the quality control and packaging/distribution of the finished product.

Problem

GF Piping Systems operates multiple extrusion sites across the US. Up this point, extrusion operator onboarding training had not been standardized, and was conducted by senior extrusion operators of various levels of experience and knowledge of best practices and standard policies. 

The quality, comprehensiveness, and effectiveness of the training solely depended on the trainer themselves.  This variability led to production orders of piping being out of specification and being discarded, ultimately hurting profits. 

Additionally, training and assessment was documented on paper (if documented at all), so there was no digital transcript or record of the learner's progress and completion.

Solution


As project lead and sole developer, I began by conducting a training needs analysis and establishing project goals. I then completed a job task analysis by shadowing a senior operator for a day. 

I designed and developed a 3-module, hybrid training curriculum.  Each module contained an online and hands-on component, with subsequent modules covering more advanced topics and responsibilities as the learner progressed through their onboarding. 

Learners would have to demonstrate competency through standardized, hands-on assessment before the trainer would 'unlock' additional modules. By chunking the training modules by job task family, this reduced information overload for the learner and allowed them to settle into the role easier.

To complete the package and support trainers, I also developed a standardized facilitator guide (and template for future training programs).

Roles and Tools