Advanced Manufacturing Technician

Advanced Manufacturing Technician

Advanced Manufacturing Technician

The TOYOTA AMT Career Pathway Program A Global Technician Development Path Advanced Manufacturing Technician CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 1

Advanced Manufacturing Technician

The AMT Career Pathway Dennis Dio Parker Assistant Manager TOYOTA North American Production Support Center AMT Program Developer North American Lead for the AMT Program CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 2

Advanced Manufacturing Technician

What Is AMT? At its core, AMT is a Career Pathway Team Member S k i l l P o i n t Internship S k i l l P o i n t S k i l l P o i n t 1-2 Yrs Career $ $ $ $ S k i l l P o i n t s $$$$$ H $ $ K-5 5th Grade Plant Tours College Visits Counselors Teachers Parents N/A S k i l l P o i n t College A.S. $$ $ S k i l l P o i n t S k i l l P o i n t 2 Yr Special Toyota Degree Program 100% Toyota Relevant High School 2-4 Yr PLTW Classroom Career Days Plant Tours College Partner Counselors Teachers Parents Recreational Days Clubs Middle School Classroom Career Days Plant Tours College Partner Counselors Teachers Parents Recreational Days Clubs 1-2 Yr GTT The TOYOTA Multiskilled Technician Path CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 3

Advanced Manufacturing Technician

TOYOTA Integrated Career Pathways K-12 TOYOTA Advanced Manufacturing Career Paths Robotics Programmable Controls Line Controllers Vision system Troubleshooting Toyota Maintenance Internship Toyota Advanced Program Manufacturing Management Program B.B.A. A.B. AMT Advanced Manufacturing Technician Program AME Advanced Manufacturing Engineering Program Electrical / Industrial Mechanicall B.S. TOYOTA Engineering Career Design Engineer TTC TOYOTA Engineering Career Production Engineer TEMA * 6 mo. – 2 years * Full-time floor experience TOYOTA Seibi Career Org Mgt.

Seibi Mgt. Seibi Tech___ TOYOTA Maintenance Career MGR AM GL____ TL____ TM _ _ Special Toyota Degree Program 100% Toyota Relevant Project Lead the Way NED New Engineer Development Lean Manufacturing Certificate Automotive Manufacturing M.B.A.

In development SKILLED TECHNICIAN ENGINEERING BUSINESS CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 4

Advanced Manufacturing Technician

And On to Other Companies K-12 TOYOTA Advanced Manufacturing Career Paths Robotics Programmable Controls Line Controllers Vision system Troubleshooting Toyota Maintenance Internship Toyota Advanced Program Manufacturing Management Program B.B.A. A.B. AMT Advanced Manufacturing Technician Program AME Advanced Manufacturing Engineering Program Electrical / Industrial Mechanicall B.S. TOYOTA Engineering Career Design Engineer TTC TOYOTA Engineering Career Production Engineer TEMA * 6 mo. – 2 years * Full-time floor experience TOYOTA Seibi Career Org Mgt.

Seibi Mgt. Seibi Tech___ TOYOTA Maintenance Career MGR AM GL____ TL____ TM _ _ Special Toyota Degree Program 100% Toyota Relevant Project Lead the Way NED New Engineer Development Lean Manufacturing Certificate Automotive Manufacturing M.B.A.

In development CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 5

Advanced Manufacturing Technician

Why AMT? AMT is an effort to secure a reliable and consistent pipeline of global quality technical talent to sustain and improve advanced manufacturing operations in the U.S. AMT is one answer to help the U.S. sustain global leadership in manufacturing, and to protect the contribution of manufacturing to the national quality of life. CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 6

Advanced Manufacturing Technician

What Is AMT? • It’s an industry-initiated career pathway – Toyota visioned the program – Toyota & Bluegrass Comm.

& Tech. College started it – Toyota and 11 additional companies in KY have grown it – 4 more Toyota plants, 4 more schools, and 2 more companies (with more coming) have expanded it. • It is a tightly coordinated, connected pathway • It is a “Pull System” pathway, and not a “Push.” CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 7

Advanced Manufacturing Technician

AMT Pathway Principles • Consistently produce technicians that are on par with the best in the world. • Every step & activity is “best practice.” • Data-based management. • Coordinate resources and partnerships. CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 8

Advanced Manufacturing Technician

AMT Pathway Principles • Coordinated connections: TOYOTA PLANT High Schools (Selected) Middle Schools (Feed the selected high schools) Elem. Schools (Feed the selected selected middle schools) Those schools with which we cannot establish an in-person connected receive a comprehensive e-mail package.

Package sent to the Superintendent, HS Principals, Counselors CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 9

Advanced Manufacturing Technician

The Pathway Steps: K-5 (5th Grade) K-5 5th Grade Plant Tours College Visits Counselors Teachers Parents N/A BEST PRACTICE FOR: 1. ENCOURAGING PARTICIPATION IN STEM 2. CREATING A FAVORABLE EXPOSURE TO MANUFACTURING * MESSAGE: ENROLL IN GATEWAY TO TECHNOLOGY • Engage 5th students. • Plant tour & school tour. Tailor to age. • Involve in fun activities which create interest and excitement around science & math. CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 10

CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 11

The Pathway Steps: Middle School Middle School Classroom Career Days Plant Tours College Partner Counselors Teachers Parents Recreational Days Clubs 1-2 Yr GTT BEST PRACTICE FOR: 1. PROMOTING STEM CAREERS 2. DEVELOPING CRITICAL THINKING 3. DEVELOPING COMMUNICATION SKILLS 4. CREATING A FAVORABLE EXPOSURE TO MANUFACTURING * MESSAGE: ENCOURAGE ENROLLMENT IN PROJECT LEAD THE WAY. • Engage Middle School students. • Plant tour & school tour. Tailor to age. • Involve in fun activities which promote STEM. • Introduce Manufacturing as a rewarding career. • Middle schoolers love robots!

CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 12

CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 13

The Pathway Steps: High School High School 2-4 Yr PLTW Classroom Career Days Plant Tours College Partner Counselors Teachers Parents Recreational Days Clubs BEST PRACTICE FOR: 1. PROMOTING STEM CAREERS 2. DEVELOPING CRITICAL THINKING 3. DEVELOPING COMMUNICATION SKILLS 4. CREATING A FAVORABLE EXPOSURE TO TOYOTA/FAME * MESSAGE: ENCOURAGE APPLICATION FOR THE AMT PROGRAM • Plant & school tours. Promote manufacturing.

• Accelerate career thinking, maturity growth. • Underclassmen: build relationships. • Seniors: recruit to AMT Program. • Engage students/parents/teachers/counselors/admins. CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 14

CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 15

16 Preparing Students For the Global Economy CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 16

PLTW Curriculum Elementary School Program Launching in 2014 Middle School Program GatewayTo Technology High School Programs PathwayTo Engineering & Biomedical Sciences COLLEGE, CAREER, & BEYOND PLTW – Leading provider of STEM education programs CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 17

America’s STEM Solution 18 Over 5,200 programs More than 4,700 schools more than 10,500teachers trained 100sof partners CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 18

97% of PLTW seniors intend to pursue a four-year degree or higher The national average is 67% PLTW – Leading provider of STEM education programs CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 19

80% of PLTW seniors say they will study STEM in college The national average is 32% PLTW – Leading provider of STEM education programs CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 20

50 University Affiliates PLTW – Leading provider of STEM education programs CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 21

Going places…together preparing students for the global economy CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 22

CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 23

The Pathway Steps: High School • At the Kentucky Program: – Visit about 20-25 high schools each year – Selected because they host PLTW program – Ask to include more: • Tech Ed / Vocational Ed • Math/Science/Honor organizations CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 24

The Pathway Steps: High School • Recruiting goal: Reach every graduate in the state. – In-person visits, relationship building, recruiting at schools close enough for travel Target: About 25 schools/year.

– E-mail package to every public school superintendent, high school principal, and counselor – E-mail package to every private school principal – E-mail package to as many home school activities as practical (states vary greatly in organization) CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 25

The Pathway Steps: 2-Year College • The “Hub” program of the pathway. • Degree program re-designed from the ground up. CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 26

• Selective program • Maximize learning • Work/study format on a day-to-day basis • Extensive non-technical student formation • Set high standards for academics and work, and … • …never compromise standards • Incentivize performance The Pathway Steps: 2-Year College CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 27

The Pathway Steps: 2-Year College 3rd Semester 4th Semester 2nd Semester 1st Semester 5th Semester General Education Technical Core Areas Internship Manufacturing Floor Experience System Troubleshooting Robots Welding & Machining Drawings Controls PLC Motors Mechanics Intro to Electricity Fluid Power Public Speaking Social Science Science Writing Math Priority 1 Mastery Start Maintenance Foundation Maintenance Introduction Production Experience Attendance – Communication – Diligence – Teamwork – Interpersonal Relations - Initiative Personal Behaviors Advanced Manufacturing Technician Program Associate Degree in Applied Science Selection Process Target Criteria: High School Graduates > 1/3 Math Ranking > ½ Class Standing PLTW Participant Communication and critical thinking skills Multiskilled Technical Foundation Floor experience and hands-on skill Excellent worker behavior on hire CHARACT- ERISTICS WHEN HIRED Manufacturing Core Exercises The DNA of Manufacturing Continue Practicing Activity Continue Practicing Activity Continue Practicing Activity Continue Practice Safety Culture Workplace Organization Problem Solving Lean Manufacturing Maintenance Reliability Good safety practice on hire 5S understanding and practice on hire Problem solving thinking and use on hire Lean mfg thinking and practice on hire Understanding of maintenance practice on hire Coach Coach Coach Coach Next Generation Technical Degree 5 Straight Semesters WORK M T W Th F WORK WORK School School 8+ Hrs / Day 40+ Hrs / Week Weekly Schedule CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 28

MONDAY TUESDAY WEDNESDAY THURSDAY FRIDAY HOMEWORK WORK SCHOOL WORK WORK SCHOOL COMPLETE MANUFACTURING CORE EXERCISES 8 Contact Hours (9+ total) 1-2 Hrs As Needed The Pathway Steps: 2-Year College Weekly Schedule CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 29

The New Model School For Manufacturing MORE REALISTIC Looks Like a Factory Feels Like a Factory MANUFACTURING SIMULATOR Central Focus Reason for Learning Toyota Troubleshooting PROCESS LEARNING Students learn in a structure sequence ORGANIZED BY FUNDAMENTAL SKILL Electricity / Fluid Power Mechanics & Fabrication TOYOTA LEARNING Safety, TPS, 5S Learning Lab Students Learn the Right Way the First Time TMMK The Pathway Steps: 2-Year College CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 30

The AMT Program in Action AMTs receive accelerated and intensive training in both verbal and written communication. Note in this photo: •Group presentation •Attendees standing, not sitting in desk •Looks and feels like a manufacturing site – not like a school. (No classrooms!) They are assessed on their communication performance by their peers. COMMUNICATION DEVELOPMEN T CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 31

The AMT Program in Action Toyota 5S Training Traditional students never get this type of training.

Companies will pay top $$$ for this training for their employees. It is estimated that AMTs receive $10,000 worth of free training and education beyond their academic curriculum. CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 32

The AMT Program in Action AMTs work in the real world at the same time that they are learning. 3 days of the week are spent in a manufacturing plant working with mentors and trainers. Their experiences and training in the program are linked to their learning in school on the other two days of the week. ADVANCED WORK EXPERIENCE CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 33

The AMT Program in Action AMTs learn an unprecedented level of problem solving and critical thinking.

Before graduating from the college program they will have deeply absorbed the Toyota 8-Step problem solving process and its principles, will have solved a real problem on the school floor and a real problem on the manufacturing floor. And they’re still 1-2 years away from potentially being hired. This level of problem solving and critical thinking analysis is rarely seen at the university level. Here an AMT student presents her school based problem to a group of visiting legislators and state-level college system administrators.

PROBLEM SOLVING CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 34

Progressive Reward $12 $16 $17 $19 $25 $31+ Powerful Message: Work Hard Do Well Get Along Keep Learning Get Rewarded! In the College phase raises are earned by a combination of Grades + Floor Evaluations Message How much do you want to study? How Involved do you want to get? CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 35

Program Results Measured Results • 100% pass rate on Toyota’s tough multidisciplinary technical knowledge test Pass rate of experienced technicians: < 50% • > 95% pass rate on all 4 major areas of the Toyota test Of external (experienced) applicants who pass, < 50% pass more than one area. • 100% pass rate on 3 of the major areas Includes the toughest area, Electricity and Control • 87% of 2013 graduates were “Honor Graduates.” Rate for the same program at the other six campuses < 30%.

CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 36

Program Results SUCCESS 70% DROP 95% 30% 5% Program Retention CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 37

Program Results Observational Results • Bluegrass Community & Technical College Public Speaking Instructor: “AMT students are coming into my class with better public speaking and verbal communication skills than my usual students at the end of class.” • David Cox, General Manager of the Power Train Plant: “My Group Leaders now “fight” to get AMT interns for their groups.” • John Dotson, Manager of TMMK Assembly Maintenance: “I have to run my AMT student out for lunch and she’s already completed a full (Problem Solving) activity that most of my team members have never done.” • Karen Price, President of the West Virginia Manufacturers Association: “The most amazing aspect is their communication skill!” • Several managers at the annual Toyota North American Maintenance Management meeting: AMTs are the best new-to-field talent ever experienced.

CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 38

Program Results Observational Results Vince Bertram, President of Project Lead the Way, a national engineering development program for K-12 education: “This model has become a national source of discussion.” “The Project Lead The Way team, consisting of our internal members and a strong national network of university affiliates, state leaders, and corporate partners, tells me there is no stronger program in the United States than Toyota’s model for training its future workforce.

“ CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 39

What Does This Mean for the College? A Paradigm Shift CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 40

Opportunities for the College • Enhanced relationship with industry • Create career pathways for students in manufacturing • Contribute to the local community • Instrumental in creating a future workforce that is globally competitive CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 41

Opportunities for the Students • Classroom concepts applied at work immediately • Work concepts applied in class workplace organization, safety, culture/attendance/teamwork • Presentation and communication skills integrated into program • Income (hourly wage, bonuses, raises) • Future employment and increased opportunities CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 42

First Class of AMTs Fall 2010 CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 43

Challenges for the College • Class schedules • Faculty and staff • Recruitment minorities/women • Implementation of activities into curriculum • Work vs. school • Outside activities • Resources CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 44

Challenges for Students • Being professional • Being on time for class • Turning homework in on time • Time management • Staying focused • Controlling the texting CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 45

CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 46

Recommendations • Buy-in from all parties from the beginning • Plan and standardize schedules in advance • Set expectations with students and faculty • Do consistent interval student performance checks • College and company communicate regularly • Engage managers in activities where possible CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 47

The Pathway Steps: Internship S k i l l P o i n t Internship S k i l l P o i n t S k i l l P o i n t 1-2 Yrs $$$$$ H $ $ BEST PRACTICE FOR: 1. First Day work readiness Runs the floor on a daily basis. 2. First Day work behaviors Demonstrated attendance, teamwork, initiative, and diligence capabilities 3. First Day Lean Manufacturing readiness Knows/practices 5S … TPS … Problem Solving • Well paid, full-time ($38,000 - $50,000 annualized) • Invaluable experience, deepens skill. • Student demonstrates comprehensive capability. • Target: Master tasks to keep shop running daily. • Flexible length allows to align to job opening.

CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 48

The Pathway Steps: Internship • At the Kentucky Program – Internship is 1-2 years. – Interns are eligible for medical and vacation benefits. – Pay is progressive based on performance. – Basic structure is: • 1st year: Master the Daily tasks to run the floor. • 2nd year: Align to a job opening. • Actual time can vary. CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 49

The Pathway Steps: Employment • Hired if: a) Successful internship, b) job opening. • About 95% of interns are being successful.

• Annual starting pay in the $60k range. • Typical is $70k - $100k with premiums and overtime. Team Member Career $ $ $ $ S k i l l P o i n t s H MEASURABLY CONTRIBUTES TO INDUSTRY BEST PRACTICE FOR: 1. Safety Improves company safety condition and goals 2. Quality Right work the first time, every time 3. Productivity Continually improves work lead time 4. Cost Lowers company cost 5. Fastest Learners for Performance Shortest learning time CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 50

The AMT Program: FAME • Toyota reaches out to other manufacturing and invites them to join the AMT program. • The manufacturing collaborative group supporting the AMT Program is known as the Federation for Advanced Manufacturing Education  FAME! • Active groups: WV FAME, KY FAME • Tennessee, Alabama, & Indiana groups starting CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 51

THE AMT Program: KY FAME • 13 companies: 10 sponsoring AMTs, 3 waiting for new AMTs.

• About 50% of AMTs are now non- Toyota. • Work collaboratively to support the program • Are a “living advisory committee.” CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 52

AMT Program: More • Professional Development – Faculty training for new programs – Training in all Manufacturing Core Exercises Safety Culture, Workplace Organization, Lean Manufacturing, Problem Solving, Machine Care – Can teach the Core Exercises to non-AMT customers – Continuing experiences in the Mfg. workplace – Part of national communication network CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 53

AMT Program: More • Fact-based Decision Making An aspect of Toyota management practice! – Comprehensive data-base in active development – Types of data: Academic (grades, etc.), work-task completions, attendance, drop reasons, work evaluations, demographics, source schools, assessment results (including ACT, SAT, other tests), special programs in all phases (e.g.

PLTW), class standing, and more. CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 54

AMT Program: More • Fact-based Decision Making Example: What we already know about PLTW/non-PLTW students coming into the program: For completers, PLTW has higher GPAs For drops, non-PLTW rate is 300% higher than PLTW • Current conclusion: Strategy to focus on PLTW schools appears to be correct and productive CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 55

AMT Program: Future • Integration of the AMTEC online curriculum as a regionally common core • Annual conference including companies, schools, faculty, and students (starts 2014) • Nationally networked program management and data management • National website, promotion, recognition, etc.

• Engagement of external researchers for mutual benefit (meaningful research for them, actionable results for us) • System to assess U.S. performance vs. global performance (skilled/technical education and work). CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 56

The AMT Program: Snapshot Today • Six AMT programs in place – Kentucky (4th year): Bluegrass CTC – West Virginia (2nd year): Bridgemont CTC – Indiana (1st Year): Vincennes Univeristy – Mississippi (1st Year): Itawamba Community College – Texas (1st year): Alamo Colleges – Tennessee (Starting): Jackson State Community College • One programs starting implementation (Aug., 2014) – Alabama: Calhoun Community College • Preparing/Studying Implementation – Missouri: 2 plants, school to be determined (Preparing) – Mexico: Universidad de Tijuana (Studying) CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 57

Newest Program: TMMTX CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 58

TMMI: 1st Class CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 59

TMMWV 2nd Class CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 60

Kentucky 4th Class KY FAME / Bluegrass Community & Technical College ADVANCED MANUFACTURING TECHNICIAN PROGRAM AMT Students 2013 Class ` KY FAME Kentucky Federation for Advanced Manufacturing Education TOYOTA 3M Central Motor Wheel G.

R. Spring Topy Link-Belt Sealing Life Bullard Florida Tile Webasto I. B. Moore CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 61

The AMT Program: Snapshot Today To date there have been over 700 visitors to the AMT Program in the past 2 ½ years. • 6 Natons – United Kingdom, Germany, Brazil, Japan, Canada, Mexico • Many companies, including from other states (incl. GE, John Deere, Fed Ex, Ford, GM) • School districts from Texas and Mississippi • Many colleges and universities • CTE and government researchers and research organizations CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 62

The AMT Program: Snapshot Today Jennifer McNelly, President of the Manufacturing Institute, part of the National Association of Manufacturers, visits to recognize the AMT Program as a national best practice.

CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 63

The AMT Pathway to Employment Team Member S k i l l P o i n t Internship S k i l l P o i n t S k i l l P o i n t 1-2 Yrs Career $ $ $ $ S k i l l P o i n t s $$$$$ H $ $ S k i l l P o i n t College A.S. $$ $ S k i l l P o i n t S k i l l P o i n t 2 Yr Special Toyota Degree Program 100% Toyota Relevant Megan as a new AMT Student Megan as mid-term AMT Student Speaking to university administrators Megan as senior AMT Student Working on the Manufacturing Simulator Megan as an AMT Intern Assigned to Assembly with Mgr. John Dotson HIRED: August 26, 2013! Megan Gant’s Pathway to Employment CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 64

THANK YOU!! Questions & Answers CIPD 313 Proceedings of the 2014 Conference for Industry and Education Collaboration Copyright ©2014 American Society for Engineering Education” 65

Global Quality Technicians Making the U.S. First in Global Manufacturing · An Education/Industry Partnership – a “co-owner” program. · Re-defines the Customer Relationship of education: Old Model: The Student is the No. 1 Customer New Model: The Student and Industry are Co-No. 1 Customers Practical Effect: Results in a better program and an almost 1-to-1 employment ratio. · Not a “technical college” - a “Manufacturing Magnet” college with the goal of preparing globally competitive technicians that will support the success of U.S.

manufacturing against our strongest international competitors. · Re-designs the learning environment. Transforms the place of learning to look/feel/function like the place of work (Classrooms are unrealistic). · Emphasis is on the “Technician” (the person) and not the “Technology.” But there’s still more technology in this program than in traditional programs. · Work/Study scholarship program, with close coordination of all activities. Pay for work will covers education expenses.

· Re-designs the curricular program: Selective program, targeting best talent from the K-12 system. 100% use of every learning minute (8 hrs/day, 5 days/week, 5 straight semesters). Every course pre-selected for maximum preparation for advanced manufacturing. Adds 5 extra-curricular semester-long modules to teach the DNA of manufacturing. Emphasizes verbal and written communication skills and key work behaviors. · Industry-led coalition pulls in additional employers to sponsor students. · Part of a larger career pathway program leading to additional education.

Canada Plants In study Missouri Plants In Discussion Mexico Plant In Discussion Toyota Team Member S k i l l P o i n t Toyota Internship S k i l l P o i n t S k i l l P o i n t S k i l l P o i n t Toyota Advanced Program $$$ S k i l l P o i n t S k i l l P o i n t S k i l l P o i n t College A.S.

Degree Program $$ $ S k i l l P o i n t S k i l l P o i n t High School Feeder Program Project Lead the Way 2-4 Yr PLTW 2 Yr 1 Month (Avg.) 6-24 Months 1-25 Yrs (Career) College Partner NAPSC and/or Toyota Plant Toyota Plant Toyota Plant $ $ $ $ S k i l l P o i n t s $$$$$ Middle School Promotionals Classroom Career Days Plant Tours College Partner Counselors Teachers Parents Recreational Days Clubs Maintenance Supervision, Management, Administration, Development TOYOTA Education Career Path Model for North American Plants Classroom Career Days Plant Tours College Partner Counselors Teachers Parents Recreational Days Clubs KEY ACTION Student continues to PLTW in HS KEY ACTION Student maintains pace with academic courses, meets performance expectation at work.

KEY ACTION Student chooses to enter special college program KEY POINT Students are “hand selected” by Toyota shop mgt.

KEY POINT Minimum pace required. Pay based on: 1. Passing classes 2. Sat work performance KEY POINT Student work can be discontinued if performance unsatisfactory KEY POINT Curriculum set by each shop to meet own needs KEY POINT As much or as little as needed by shop KEY POINT Lowest cost to company to get advanced training KEY ACTION Student shows capability to master complex training KEY POINT Toyota makes determination that trainee will make a capable employee in all respects KEY POINT Time to align open position to trainee (time is flexible) KEY POINT Time can be extended with competitive pay.

KEY POINT Each stage is coodinated with the next in both: A) Education B) Pay Progression KEY POINT Positive incentive to perform and progress is continuous OVERALL KEY POINTS KEY ACTION Trainee is hired as an entry level STM. External Hires (already skilled) F u n d a m e n t a l S k i l l s A s s e s s m e n t KEY POINT Minimized muda. Maximizes cost saving. Special Toyota Degree Program 100% Manufacturing Relevant KEY POINT All Toyota Fund Skills + add’l skills are taken before hire. KEY POINT Schools/programs already identified H $ $ $$$$ T C A TOUR 1/Yr Student/Parents Family Engagement School Engagement Kentucky Plant Fall-2010 KEY POINT Only hire if ALL Priority 1 Tasks Mastered.

KEY POINT All take Fund. Skills Assmt. And are placed into program at appropriate point ACADEMIC LEARNING (16 hr/week) Electrical & Control Fluid Power Mechanics Fabrication Industrial Troubleshooting 5 Straight Semesters 8 hr/day, 5 days/week MFG Core Exercises (After School/Work Day) 1st Semester: Safety 2nd Semester: 5S 3rd Semester: Lean Mfg. 4th Semester: Prob. Solving 5th Semester: TPM WORK LEARNING (24 hr/week) Production Maintenance Intro Preventive Maint. Work Priority 1 Mastery WORK VALUES (Continuous) Attendance Diligence Teamwork Interpersonal Relations Conflict Resolution Initiative West Virginia Plant Fall-2012 Indiana Plant Fall-2013 Mississippi Plant Fall-2013 KEY ACTION Demonstrates ability to fully & satisfactorily perform on the floor in all conditions Texas Plant 2013 M a n u f a c t u r i n g C a r e e r s P r o m o t i o n A c t i v i t y D r e a m I t ! D o I t ! D r e a m I t ! D o I t ! Engage These Demographics T C A Parent Student Parent Teacher Counselor Administration Initial Implementation Model Alabama Plant in Preparation 1-2 Yr GTT Tennessee Plant Starts Fall-2014 PAY Grades + Work Evaluations Students earn their own raises.

The Message: How hard do you want to study? How involved do you want to be on the floor? Best Education Career Pathway in the U.S.

Career Pathways Partnership 2013 Excellence Award winner! National 1st place Toyota AMT Program (NAPSC) Gateway to Technology

Integrated Career Path Potential Bachelors Degree Continuations Support the technical education community Associate Degree Program 3rd Semester 4th Semester 2nd Semester 1st Semester 5th Semester General Education Technical Core Areas Internship Manufacturing Floor Experience System Troubleshooting Robots Welding & Machining Drawings Controls PLC Motors Mechanics Intro to Electricity Fluid Power Public Speaking Social Science Science Writing Math Priority 1 Mastery Start Maintenance Foundation Maintenance Introduction Production Experience Attendance – Communication – Diligence – Teamwork – Interpersonal Relations - Initiative Personal Behaviors Advanced Manufacturing Technician Program Associate Degree in Applied Science Selection Process Target Criteria: High School Graduates > 1/3 Math Ranking > ½ Class Standing PLTW Participant Communication and critical thinking skills Multiskilled Technical Foundation Floor experience and hands-on skill Excellent worker behavior on hire CHARACT- ERISTICS WHEN HIRED Manufacturing Core Exercises The DNA of Manufacturing Continue Practicing Activity Continue Practicing Activity Continue Practicing Activity Continue Practice Safety Culture Workplace Organization Problem Solving Lean Manufacturing Maintenance Reliability Good safety practice on hire 5S understanding and practice on hire Problem solving thinking and use on hire Lean mfg thinking and practice on hire Understanding of maintenance practice on hire Coach Coach Coach Coach Next Generation Technical Degree 5 Straight Semesters WORK M T W Th F WORK WORK School School 8+ Hrs / Day 40+ Hrs / Week Weekly Schedule K-12 TOYOTA Advanced Manufacturing Career Paths Robotics Programmable Controls Line Controllers Vision system Troubleshooting Toyota Maintenance Internship Toyota Advanced Program Manufacturing Management Program B.B.A.

A.B.

AMT Advanced Manufacturing Technician Program AME Advanced Manufacturing Engineering Program Electrical / Industrial Mechanicall B.S. TOYOTA Engineering Career Design Engineer TTC TOYOTA Engineering Career Production Engineer TEMA * 6 mo. – 2 years * Full-time floor experience TOYOTA Seibi Career Org Mgt. Seibi Mgt. Seibi Tech___ TOYOTA Maintenance Career MGR AM GL____ TL____ TM _ _ Special Toyota Degree Program 100% Toyota Relevant Project Lead the Way NED New Engineer Development Lean Manufacturing Certificate Automotive Manufacturing M.B.A. In development Many verbal presentations in realistic settings (e.g., not sitting in classroom seats) Learning Workplace Organization before real application activities.

Views of the AMT Program in Action Learning from experts in the workplace during company- based work assigments. Presenting a real floor-based Problem Solving activity for a visiting university.

Building Teamwork through strong Program identity and cohort organization Nationally Standardized Multiskilled Associate Degree Engineering Technology Bachelors Degree (U.K./EKU/NKU Engineering Bachelors Degree (U.K.) Business Management Bachelors Degree (Northwood U.) Career & Tech. Education Bachelors Degree (NKU and/or /EKU) G A P 1 3 2 4 5 6 Coordinated Programs Student completes Multiskilled Associate degree, continues and completes a business bachelors through Northwood University. NU is 100% articulated with the Associate Degree. Student starts and completes an Engineering bachelors at U.K.

Student completes Multiskilled Associate degree or starts an ET program at UK, continues and completes an Engineering Technology bachelors through U.K. The goal is to actively work the design and rigor of both programs to achieve 100% use of A.A.S. work toward the UK or UL degree. Student completes Multiskilled Associate degree or starts an ET program at UK or EKU, discovers an emerging interest in Engineering and has the qualifications (math,etc.) to re- track and change majors. This become a small but new pool of candidates for UK engineering programs.

1 2 3 4 Student starts an Engineering bachelors at U.K.

but cannot complete. Student re-tracks to Engineering Technology and completes a bachelors degree. This 1) keeps students in college and in the UK engineering dept. who would otherwise transfer or drop-out or: 2) keeps students in the UK engineering dept. who would otherwise transfer to programs in other depts. 5 Student completes Multiskilled Associate degree at BCTC or starts a C&T program at NKU or EKU and completes a C&T bachelors through NKU and/or EKU. UK / NKU / EKU can partner for a close alignment of the ET and C&T programs to support teacher education, and perhaps allow for a double major for interested students.

6 A High School___ Middle School___ K-5 School Active discussion with KDE in progress. 1st level UK articulation complete. Working on next. Specific schools (UK, NKU, EKU) are used to illustrate work at the Kentucky location. As model moves to each plant site local universities would become partners for engineering and for career & technical education.

Kentucky Plant Example Best Education Career Pathway in the U.S. Career Pathways Partnership 2013 Excellence Award winner! National 1st place Toyota AMT Program (NAPSC)

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