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INTRODUCTION
Every company should be fully committed to the continuous development of its staff, in
the same ways as we continuously develop our services. This will be achieved by helping all
staff identify and meet their own job and business related development needs. This policy will
ensure that we have the adaptability and flexibility to thrive and succeed as a business. To do
this, all line managers, through the Performance Review process, will
• Ensure that staff have a level of knowledge and skill to fully perform their role
• Encourage staff to develop within their current role
• Look for potential, and find ways for staff to demonstrate potential
• Recognize and reward staff development (utilizing it wherever possible)
• Create a learning culture by providing opportunities for learning
Equal opportunities
All staff are entitled to and can expect to receive training they need to carry out their
current role. This includes fixed-term contract or short-term contract staff.
Permanent employees can expect to benefit from further commitment for each individual
to devote at least 5 days a year towards training and development. First priority will be towards
job-related training, but we will also encourage individuals to undertake personal development
training. This may entail taking professional qualifications;
Training should not be viewed purely as “attending a training course”. There are a
variety of different methods that can be used to help train and develop individuals and Personnel
Services will be happy to help individuals and managers select the most appropriate method.
For-example, using open learning materials; computer-based packages; videos or CD-ROMs;
e-learning; and reading literature, to name but a few.
Shared responsibilities
It is recognizes the need for everyone to learn and develop their skills on a continuous
basis and will support individuals to help them achieve this.
Equally, the company expects individuals to take on some responsibility for their own
self-development. For example, identifying suitable training activities (with the help of line
managers and Personnel Services) and adopting a flexible and positive approach to any training
and development that is identified with them.
Once someone has experienced a training and development activity or learning, we will
measure its impact and effectiveness on individual performance and the organization. Again,
line managers are expected to be part of this process by defining the performance standards (or
measures) when setting objectives and deciding on the methods that they will use to evaluate
the learning. (Personnel Services will of course be available throughout the process to provide
guidance and support).
There are three key stages that will be used to evaluate training and development:
Performance: Evaluation at this level looks at the impact of a learning experience on individual
performance at work. Key to this area of evaluation will be the need to have established smart
learning objectives prior to the learning experience so that when evaluation takes place there
are measures to use. For example, an important learning objective for a junior secretary
attending a Word training course may be “to produce typed correspondence with no spelling or
typographical errors.” In this example, a manager would be able to evaluate the secretary’s
performance using a measure of “no spelling or typographical errors”. Ideally, evaluation on
performance should take place approximately 3-4 months after the learning activity. Line
managers should undertake this evaluation and send a copy of the results to Personnel Services.
In summary then, Personnel Services will evaluate training and development at the
reaction and organizational levels, and line managers will be responsible for evaluating the
effectiveness of training and development at the performance level. However, there will be some
types of learning activities, for example attending conferences or seminars, where it may not be
appropriate to undertake any evaluation. If any doubt, please contact Personnel Services.
To assist line managers, there are a variety of methods that can be used to measure the
effectiveness of the learning. Some of these include:
Participant self-assessment
Written or practical tests
Structured interviews
Questionnaires
Feedback – for example, internally from colleagues, peers, and managers and/or
externally from partners, customers or clients
Qualifications obtained
Line managers should contact Personnel Services, who will be pleased to help set-up an
evaluation method to use to measure the effectiveness of a training activity.
Funding for training and development will be paid from a central training budget, therefore
the Head of Personnel Services must approve any training and development that involves a
Financial cost before any financial commitment is made. Details of how to apply for a training
and development are explained under the section headed “Selecting a training provider and
applying for training”.
In addition to job-related training and development, company also recognizes the need
to help individuals to improve within their chosen career path by encouraging individuals to
gain professional/vocational/academic qualifications. With this in mind, company has
established a company sponsorship scheme whereby full or partial sponsorship will be provided.
Information about the scheme can be found under the section headed “Company sponsorship”.
Time off to attend training courses
Where an individual needs to attend a training course funded by company, time off
during working hours will be given to attend the course. Individuals are expected to travel to
and from a training venue within the normal course of the day. Where company is providing
For purposes of this discussion we will divide the training process into three phases:
(1) Needs identification
(2) Training Systems (courses, modules, training aids, presentation, instructors, records)
(3) Evaluation
It is important to know exactly what you are doing, and why, when undertaking ITN.
This is the reason we have included material to help you make considered decision and take
thoughtful action. You will find, however, that the return on the investment you make in fully
understanding what ITN is all about will make it well worthwhile.
Training needs identification detects and specified the training and development needs of
individuals within organization and of the organization as a whole.
Training needs analysis follows on from need identification and determines the most effective
and appropriate ways in which the needs might be met. If can, of course, lead to decisions that
there should be no training provision in view of the limited scale of the needs, the cost of
provision future development envisaged, and so on.
Within the identification and analysis of these ‘need’ the actual nature of the need must be
defined. A ‘need’ is not a ‘want’.
Identification of an individual’s needs has been a result of the question ‘what’ sort of
training do you want? Effective training and development in an organization depends on the
need for the improvement of human performance being identified and satisfied by the provision
of appropriate development opportunities. ‘Wants’ can frequently be ‘need’, but the analyst
must be certain of the value of any aspect raised and eventually provided.
ITN is as important in the training process as the training itself and subsequent evaluation.
ADVANTAGE OF ITN
DISADVANTAGE OF ITN
The list of disadvantages is considerably smaller than the benefits of advantages. The only one
of any significance is the need for a skilled person to be employed and consequently the use of
that person’s time. This has been quoted earlier as one of the common criticisms of ITNs.
If the trainer alone is responsible for conducting the analysis in addition to all the other
areas of work for which they are responsible, this may be a justifiable criticism. Organization
open to criticisms of over-uses and wastes of money spent on unnecessary training. So every
attempt must be made to identify and analyze the needs accurately.
Production records, quality control reports, grievances, safety reports, absenteeism and
turnover statistics, and exit interviews of departing employees may reveal problems that should
be addressed through training and development efforts. Training needs also may become
apparent from career planning discussions or performance appraisal reviews. Supervisors see
employees on daily basis and thus are another source of recommendations for training. The HR
department also reviews self-nominations to learn whether the training actually is needed. Self-
nomination appears to be less common for training situations but more commons for
development activities.
A job analysis should focus on what the trainee needs to be able to do to perform the job
satisfactorily. In ITN, a job analysis should take both a worker and task oriented
Approach. A worker oriented approach focuses on the skills, knowledge and ability to perform
the job. These might include elementary notions, job demands, and the specific human behaviors
involved such as division making, communication etc. a task oriented approach focuses on a
description of the work activities performed. These are typically expressed in terminology used
by job incumbents and would involve a description of how, why, and of when a worker performs
an activities preferred to as a job description.
The organization has objectives that it wants to achieve for the benefit of all stakeholders or
members, including owners, employees, customers, suppliers, and neighbours.
These objectives can be achieved only through harnessing the abilities of its people, releasing
potential and maximizing opportunities for development.
Assumption about people:
1. People have aspirations, they want to develop and to learn new abilities and use them.
2. In order to learn and use new abilities, people need appropriate opportunities, resources, and
conditions.
3. Therefore, to meet people aspirations, the organization must provide effective and attractive
learning resources and conditions.
4. There needs therefore to be a match between achieving organizational goals and providing
attractive learning opportunities.
If our aim is to ensure that learning opportunities match closely the aims and goals of the
organization, than an effective ITN process enables us to do this. It will then be possible to
achieve our other training objectives, see:
We need good ITN processes in order to provide then learning opportunities required
achieving the goals of the organizations.
• In order to achieve our objectives we need our people to question the way we do things.
• Therefore our people need to learn to question the way we things.
The training need was about learning to question the way we do things. The solution was not
direct training in questioning, but a subtler longer-term process of encouraging employees to
take an active involvement in their own development, thus increasing their commitment to
learning, to their work, and to the organization as a whole. It will useful to consider how the
concepts of training need and ITN have evolved over recent decades.
Level of performance and need
Performance at this level requires two sets of learning in addition to modes 1 to 5. Here we
are concerned with doing “new and better things”, and therefore learning has to concentrate on
a more sophisticated and complex set of factors.
• Connecting, i.e. making connection between things, events, and people, and allowing
integration and synergy to be achieved. We thus learn to work better with others, and
particularly with people from different disciplines, who may have different perspectives and
assumption, all of which need accommodating.
• Dedicating, where we learn to work out of a sense of purpose – why we are doing something,
and why we are doing something, and why we are doing it at a certain time and in a particular
way. This should mean that we develop a clear sense of “what is in it” not just for ourselves,
but for our colleagues, the organization as a whole, and the wider community.
These concern the performance of the organization as a whole. Information about this
overall performance may identify areas of need either for training or other interventions.
In this case ITN is about finding out how efficiently a particular team or group goes
about its business and meets its current objectives.
Individual needs
These concern the performance of one or more individuals (as individuals, rather than
as members of a group). Again this information may identify specific needs.
Here ITN is about finding out to what extent individuals need to learn or be trained
• To bring their current performance up to the required level
• As a result of changes in methods and processes that call for new competencies and skills.
Here ITN is about looking at the extent to which individuals need to learn or be trained
in systematic, continuous improvement skills and how to take initiatives.
In Individual, group, and organizational learning needs are brought together at each of
the three levels of performance, showing the wide range of what we may need to consider when
carrying out a thorough training-needs analysis.
STUDY OF NEEDS OF TRAINING
In Dabur India Ltd., Sahibabad across training is customized product wise. If any
defect comes in a product or process, a training session is initiated to eradicate root cause.
There are normally two work stations in production.
1. Critical station
2. Normal station
At critical work station an efficient worker should produce 5000 to 6000 units in one shift. At
this work station minor job is done.
At normal work station an efficient worker should be produce 8000 to 10000 units in one
shift in normal circumstances.
In this company there are two types of worker are working.
1. Permanent worker
2. Temporary worker
A worker get the permanent job after the good and consistent performance in the company,
these people are well experienced in their relative jobs.
Temporary worker is a layman. They don’t know anything about the work, so these types of
people require training.
When a new person joins the company, he got the training about the safety and
maintenance. For getting these training he is send in technical training cell (TTC). In TTC he
has to go some basic knowledge and instruction, which is given by the just senior boss. That
person is called line in charge. During the training a person gets the job. He is watched by the
line in charge. At any point the line in charged found any fault in the work, the line in charge
instructed at that time, so that the worker does the job in a proper way and come out with zero-
defect product.
There are several types of operations in the production.
• Ink filling
• Stopper
• Point tipping
• Capping
• Packing
After the TTC training employees are divided among various teams and send to the different
operations, on the different operations. A line-in charge is there, who will watch each and every
steps during the work. If any fault in the work is found, he takes that serious and instructs to
remove the fault immediately.
After some experience the worker is transferred from one operation to another operation
area. Where same procedure is performed. He works and if any confusion get regarding the job,
he may ask the line in charge or if line in charge see any fault during the operation, he educates
the worker to do the job better. This process is repeated on each and every operation. This is
how each and every employee is familiarized to the job. The main advantage of this job rotation
is, if any worker does not come on the particular day, that place can be filled by any other
worker and the works progress without any interruption. After job rotation and getting
experienced the entire worker divided into three groups,
• Highly efficient
• Efficient
• Adequate
If a person can handle all the machines related to any particular job. That worker is called
highly efficient worker. After getting training 40% out of them became as highly efficient
worker. These workers are very efficient and can handle any situation during the work. He can
work on any machine at any time without any problem. These people can take decision at the
critical point of time. So that these type of worker are called highly efficient worker.
After highly efficient the second category is called ‘efficient’. In this category those type
of person are master in their job. He is master in one job. In this category 50% worker comes.
These types of people are well known people in their particular job. They are not able to handle
the different machines. They feel problem in some job.
After that the third category comes, that is called adequate. This type is not beneficial
for the company. So that they are not acceptable. They have less knowledge and not will to
work.
Highly efficient person is well-known about their job. He can handle any situation. So
that this type of people doesn’t require training.
Efficient people are master of just on job. So that they need training to be highly efficient
worker.
Company is giving training to the efficient worker. For them there are three types of training;
• Counseling
• Give the opportunity to work with highly efficient worker.
• Give the expert knowledge about the work.
In counseling the instructor or line in charge counsel the worker. A line in charge tries
to motivate the worker to do their job in proper way. This is a verbal communication. With the
help of words a senior person tries to make them as effective as highly efficient worker.
The second option “provide them opportunity to work with highly efficient people”
helps those people to learn. During the work he can watch how the highly efficient people work?
How can they handle the situation? They got the idea about the problem, which may be arising
during the work. They also get the idea about dealing those types of problems. This way an
efficient worker is developed to be highly efficient worker.
Before start working every worker should get the knowledge about the job profile.
Without proper knowledge no one can perform better. There must be some defective in the
product due to less knowledge about the production process. So specific knowledge is essential
for zero-defect product. This is the duty of management to educate them and provide full
knowledge about the production process and quality control.
For adequate people company has some other way for giving them training. The work
pressure is the best way for make them work. Under this the adequate person is send to work
between two highly efficient workers. Highly efficient people can work faster than adequate
person. So from both sides he faces the pressure for work faster and effectively. This way an
adequate worker can be the efficient and highly efficient worker for company. In any company
some factor effect the training:
• Strategies changes
• Technical changes
• Matter of cost saving
If the top management of the company want to change their strategies. Here company
wants trained people for work. So firstly company looked for the experienced people, but it is
very difficult to get trained people. So they hired semi- skilled people and after joining them
they give them training. So that this can work effectively and according to the requirement of
the company.
If company wants some technical change in product, they also require trained people for
work. Technical change requires more technical people. If company wants to retain the same
people who are working form last sometimes then company has to give them training. After
getting training a worker can adjust in any environment and work effectively.
Today’s era is the cost cutting era. In the intensive competition cost of the product is
very important. We can’t survive in the market with high cost. So we need to cut the cost of the
product. For cutting the cost we need more trained worker who can work faster an quickly. So
that the production time can be reduced. At lastly we can get the low price product.
So that in every area we need trained people. For getting trained people we have to make
them trained by giving training.
METHODOLOGY OF TRAINING
The choice of methods depends on the knowledge and experience of the teacher or trainer.
The choice of the methods should take into consideration the intellectual level and
educational background of the participants and the participants’ age practical experience.
Some methods are more effective than others in achieving certain objective.
Choice methods depend on the social and cultural factors in the environment. Now many
participative methods are accepted and used in management training.
It also depends on the time and the availability of resources and infrastructural facilities.
Types of training
Job instruction
Training Job rotation
Apprenticeships
Coaching
Vestibule training
Induction or Orientation training:
Induction or orientation may be defined as a process of guiding and counseling the
employee to familiarize him with job situations. The induction process accomplishes several
objectives including formation of a favorable impression and attitude, development of the
feeling of belongingness and facilitation of learning and teamwork on the part of the employees.
The content of the induction program should be predetermined in the form of a checklist
specifying the topics to be covered. Attempts are to be made to follow-up and assess the program
by interviewing the new employees as a measure to correct the gaps in the knowledge and
attitude of the employees.
This is based on similarities in training on several specific jobs. This type of training can
be imparted in a classroom or on the job. It is performed by a foreman or a group leader. Its
advantages arise in so far as it is realistic and economical and does not hamper production as
well as necessitate from classroom to job situations.
Limitations of rank-and-file job training:
The trainer may be an incompetent.
Teacher The shop floor may be busy.
There may arise heavy production losses.
Supervisory training:
Supervisory training needs reveal utmost divergence in view of divergent duties of
supervisors. Employee attitude surveys help in identifying area of supervisory training.
Likewise, supervisors themselves may be requested to indicate the areas where they need
training.
Frequently, these surveys indicate that supervisors need training in human relations,
production control, company policies and how to instruct. Supervisory courses consist of job
methods training (JMT) and job relations training (JRT). The JMT helps the supervisors to
improve methods in their departments, while the JRT helps them in handling human relations
problems in their departments.
ON THE JOB TRAINING:
On the Job techniques are conducted in the real job settings. On the job methods usually
involve training in the total job. These methods are typically conducted by individuals, workers,
supervisors.
The main advantage is that the trainees learn while actually performing their work,
which may minimize the training cost. They also learn in the same physical and social
environment in which they will be working once the formal training period is completed.
Types of on the job techniques:
Job instruction
Training Job rotation
Apprenticeship
Coaching
Vestibule training
Advantages:
Easy organized
Realistic
Stimulates high motivation
Speeds up worker’s adjustment
Less costly
Disadvantages:
The disadvantage of this method is that the assigned instructor may be a poor teacher.
The worker may haste for immediate production, so the actual cost may increase.
JOB ROTATION:
Some trainers move a trainee from job to job. Each worker move normally is preceded
by job instruction training. This is a method of training wherein workers rotate through a variety
of jobs. Thereby providing them a wide exposure. Trainees are placed in different jobs in
different parts of the organization for a specified period of time. They may spend several days
or even years in different company locations. In this way they get an overall perspective of the
organization. It is used with both blue-collar production workers and white collar managers and
it has many organizational benefits. Job rotation creates flexibility, during manpower shortages,
workers have the skills to step in and fill open slots. The method also provides new and different
work on a systematic basis, giving employees a variety of experiences and challenges.
Employees also increase their flexibility and marketability because they can perform a wide
array of tasks.
Apprenticeship:
An apprentice is a worker who is learning a trade but who has not reached the state
where he is competent to work without supervision. It is particularly common in the skilled
trades. In organization a new worker is “tutored” by an established worker for a long period
of time. An apprenticeship lasts from two to five years. Each apprentice is usually given a
workbook consisting of reading materials, tests to be taken and practice problem to be solved.
This training is used in such trades, crafts and technical fields in which proficiency can be
acquired after a relatively long period of time in direct association with the work and under the
direct supervision of experts. Training is intense, lengthy and usually on a one to one basis.
Increasing national attention is being paid to workforce preparation in the United States.
This stems from the growing realization that America's ability to occupy a leading competitive
position in the emerging global economy hinges, to a large degree, on assuring that the nation's
workforce is second to none. Today, unfortunately, this is not the case.
Employers frequently report that significant numbers of young people and adults alike
exhibit serious educational deficiencies and are ill-equipped to perform effectively in the
workplace. As a consequence, leaders from industry, labor, education, and government are all
grappling with how to design educational reforms and education/training strategies that will
improve the skills of America's current and future workforce.
In the spirit of this reform, one particular training strategy -- apprenticeship -- has
captured the interest of many policy makers, educators, and others who are involved in the
national reform movement. Its growing appeal comes as no surprise and, perhaps, is long
overdue. Experience both in the U.S. and growing abroad has repeatedly demonstrated that
apprenticeship is a highly effective strategy for preparing people for work. The bulk of
apprenticeship programs offered in the U.S. and its territories are in the building trades and
manufacturing industries, but there is significant potential to develop apprenticeship programs
in a variety of other industries.
The rush to embrace apprenticeship, however, is leading to efforts that could undermine
the very pillars of its value. For example, in some instances, apprenticeship is being viewed as
a generic concept -- one that can be loosely applied to a variety of learning situations. Likewise,
others have coined such terms as "youth apprenticeship" to characterize various school-to-work
transition programs. Such thinking, while understandable in an environment that begs for
creativity and innovation, may be more harmful than helpful to the cause.
Vestibule training:
Vestibule training is a type of instruction often found in production work. A vestibule
consists of training equipment that is set up a short distance from the actual production line.
Trainees can practice in the vestibule without getting in the way or slowing down the production
line. These special training areas are usually used for skilled and semiskilled jobs, particularly
those involving technical equipment.
Vestibule is small, so relatively few people can be trained at the same time. The method is good
for promoting practice a learning principle involving the repetition of behaviour.
Behaviour Modelling
According to social learning theory, most human behavior is learned observationally
through modeling. When social learning theory is applied in industrial training programmers, it
is commonly referred to as “behaviour modelling”. Used behaviour modelling to improve the
interpersonal and communication skills of supervisors in dealing with their employees.
The topic was first introduction by the trainers after which a film was shown to the
trainees which depicted a supervisor model effectively handing a situation, followed by a set of
three to six learning parts that were shown in the film immediately before and after the model
was presented.
A group discussion is them held in which the effectiveness of the method is discussed.
After this, the practice session starts in which one of the trainee assumes the role of an employee.
And then, feedback from the training class is given on the effectiveness of each trainee in
demonstrating the desired behaviour.
At the end of each training session, the trainees are given copies of the learning points
and are asked to try and apply them to their jobs during the following week. It has been found
that this programme has had desirable effects on learning, behaviour and performance criteria.
There creation of the behaviour may be videotaped so that the trainer and the trainee can
review and critique it. When watching the ideal behaviour, the trainee also gets to see the negative
consequences that befall someone who does not use it as recommended. By observing the
positive and negative consequences, the employee receives vicarious reinforcement that
encourages the correct behaviour.
12. Fish Bowl Exercise
It is essentially used in providing skills in understanding human behaviour. It effectively
uses group interaction to develop in the participants a degree of self-awareness. The primary
objectives of the method is to inculcate in the participants the discipline of observing others and
on the basis of this, provide objective and constructive feedback and to learn about oneself, ones
behavior and personality as seen through the eyes of others and consequently to overcome
weaknesses and improve upon strengths.
The aspects to which the fish bowl exercise can be put to effective use are; individual
and group behaviour , content of communication, roles individuals paly in groups, intergroup
conflicts, level of participation, dynamics of group problem solving and decision making and,
inter personal relations.
The exercise can involve up to 25 participants seated in two concentric circles( one inner,
the outer).the inner circle is the target group, members of this group will either discuss a
preselected topic or move towards completion of a group task. After the discussion by the
members of the inner group, the outer group is asked to comment on the content and more
importantly the dynamics and group process of the inner group members
Participants must learn to provide feedback with clarity and precision. Feedback must
never be critical or it loses its constructive nature. After one cycle of the exercise is completed
the outer group will change places with the inner group and become the target group, inner
group member become observers and the exercise is repeated.
There are several non-group methods involving an assessment of each individual’s strengths
and weaknesses.
Counselling:
It helps the trainees to observe their weaknesses and involves measures to overcome them.
It is related to periodic appraisals of ratings. Specifically counselling purports to help the
subordinates to do a better job, provides a clear picture of how they are doing, build strong personal
relationships and eliminate, of at least minimize anxiety.
Understudies System:
In this the trainees work directly with individuals whom they are likely to replace.
However, it is disappointing as a training because of a likelihood of an imitation of weak as well
as strong points of the seniors.
Special Project Arrangements;
These are likely to be highly effective training systems. In these systems, a task force is
built representing varied functions in the company. The special project enable the trainees to
achieve knowledge of the subject assigned as well as to learn how to deal with others having varied
viewpoints.
Some their training methods:
Telephone Training Sessions are for individuals or small groups (up to five people).
During a Telephone Training Session we will evaluate your specific needs, tailor a session to your
needs and provide you with more advanced tips. Register for a session that is convenient for you.
Once you schedule a session we will contact you on the date and time specified to complete the
training.
Distance Learning Sessions are reserved for groups of more than five people up to 18
people. Each session utilized both presentation and live demonstrations. Sessions last
approximately 45 minutes to an hour.
SKILL TRAINING
Proper training can be as important as the equipment used and other characteristics of the job.
The money annually paid for training by business and industry also demonstrates the
importance of training. It has been estimated that American business firms spend more than $30
billion per year on training and development, with some estimates running as high as $100 billion
Motorola, Inc. alone spends about $44 million annually on employee education.
Another indication of the importance business and industrial firms attach to training is the
estimate, made a few years ago, that some forty five thousand employees across the United States
were assigned full-time to training and development activities. Since then the figures have no
doubt grown.
This broad definition of training includes both skills training, which is usually of a
technical nature and has a short-term focus, and management and career development programs,
which are aimed at educating employees above and beyond the immediate technical requirements
of their jobs in order to increase the organizations present and future ability to attain its goals.
Thus, management and career development tend to be more future oriented than skills training.
The purpose of skills training is to bring the competencies of individuals up to desired
standards for present or near-future assignments & develop new skills and knowledge to replace
those that have become obsolete as a result of technological organizational changes. The seven
major steps, as shown in figure are the following:-
1. Determining the need for skills training.
2. Translating skills needs into training objectives.
3. Formulating the budget.
4. Selecting trainees.
5. Choosing a training method.
6. Selecting and educating trainers.
7. Determining evaluation procedures.
5S TRAINING
What Is 5S?
The five S stand for the five first letters of these Japanese words:
Seiri
Seiton
Seiso
Seiketsu
Shitsuke
Calling this principle 5S is a good way to remember its content.
5S is a set of techniques providing a standard approach to housekeeping within Lean
Manufacturing.
It is often promoted as being far more than simply housekeeping and some of the
elements described below certainly move into broader areas.
A cornerstone of 5S is that untidy, cluttered work areas are not productive.
As well as the physical implications of junk getting in everybody's way and dirt compromising
quality, people are happier in a clean and tidy environment and hence more inclined to work hard
and with due care and attention.
Naturally enough, the elements of 5S are all Japanese words beginning with the letter S.
Since their adoption within Western implementations of JIT, or Lean Manufacturing, various
anglicized versions of the terms have been adopted by different writers and educators.
These are listed below against the individual elements and it can be seen that none are entirely
satisfactory.
There are some symptoms by which we are able to know that we require 5s training
methodology.
Space is crowded with parts and tools.
Unneeded items are stacked between workers.
Excess inventory on the floor.
Excess items and machines make it difficult to improve process low.
Equipment is dirty and a collection point for miscellaneous material.
Needed equipment such as tools is difficult to find.
3. Seiso (Shine)
Anglicized as Cleanliness but again the initial S can be retained in Shine, Sweeping.
There is a more practical element in that if everything is clean it is immediately
ready for use.
We would not want a precision product to be adjusted by a spanner that is covered in grease
which may get into some pneumatic or hydraulic fittings. We would not wish to compromise a
PCB assembly by metallic dust picked up from an unclean work surface. Other issues are health
and safety (people perhaps slipping in a puddle of oil, shavings blowing into people's eyes) and
machine tools damaged by coolant contaminated by grease and dust.
The task is to establish the maintenance of a clean environment as an ongoing, continuous
programme.
Sometime should be set aside for cleaning each day, or each shift. (We may have
cleaners who come in a sweep office floors, and even clean the floor in a production area, but
they do not clean the production equipment. Even if they did, this would miss one of the
opportunities available - an operator cleaning and lubricating his machine tool will spot worn
or damaged components.) Cleaning then begins to impinge upon what we already know as
preventive maintenance.
Cleaning critical components of a piece of equipment is already one element of the
activities carried out under the PM banner
The implementation of Seiso revolves around two main elements.
The first is the assignment map which identifies who is responsible for which areas.
The second is the schedule which says who does what at which times and on which days. Some of
these happen before a shift begins, some during the shift and some at the end. Again, this is very
reminiscent of what we do when adopting PM.
The standard texts such as that of Hiroyuki Hirano then go on to talk about establishing
the shine method for each item / area. This includes such elements as agreeing an inspection step
at the beginning of each shift, establishing exactly how each activity within the programme is to
be carried out. A key aspect is very much akin to set-up reduction (or SMED) in that we should
be aiming as much as possible to internalize the activities - in other words, to minimize the
downtime needed to keep the facilities clean.
Finally the standard texts talk about preparation - making sure the equipment needed to
clean is always available, always ready for use. The best parallel to this is, again, with set-up
reduction, which itself is often compared to Grand Prix teams preparing to change tires. As with
many such topics, we are talking about here is to a large extent simply common sense. We do not
wish to allocate 5 minutes for a bed to be swept on a piece of grinding equipment if the operator
is going to spend 4 minutes finding his brush.
4. 5s Seiketsu (Standardization)
This is best described as Standardized cleanup, but other names adopted include
Standardization (not to be confused with the second pillar), Systematization and Sanitation.
Seiketsu can be the thought of as the means by which we maintain the first three pillars.
There is, obviously, a danger in any improvement activity that once the focus is removed
and another 'hot button' grabs management attention, things go back to the way they were before.
Seiketsu is the set of techniques adopted to prevent this happening. Basically this involves setting
a schedule by which all the elements are revisited on a regular basis - usually referred to as the '5S
Job Cycle.'
The first step in the cycle is a periodic review of the area, perhaps involving red tagging
but certainly involving people from other areas of the business.
This will identify where standards have slipped - for example where pieces of tooling or
fixtures which are used infrequently are no longer being put in the remote location agreed at the
outset and consequently a bench is now cluttered with the regular items buried under a pile of
irregular. (In other words, the Seiri phase is undertaken periodically - usually monthly, perhaps
quarterly.)
The second step is to undertake Seiton activities as required - that is, as prompted by the first step.
Finally within Seiketsu people from other areas visit and cast a critical eye over the state of the
area.
Again, an external assessor may notice degradation that is not clear to the people who
work in the area. Hirano talks of a checklist within Seiketsu whereby the external visitors mark
the area on a number of key criteria defined at the outset of the programme. For example, are the
storage areas still clearly defined? Does the tool rack still have clear outlines or profiles for each
tool to be stored in it? Does the area meet the general standards of cleanliness?
i. Shitsuke (Sustain)
The final stage is that of Discipline.
For those who wish to retain the use of initial S's in English this is often listed as Sustain or
Self-discipline.
There is a fundamental difference between Seiketsu and Shitsuke.
The fourth pillar is the introduction of a formal, rigorous review programme to ensure that
the benefits of the approach are maintained.
The fifth pillar is more than this; it is not simply the mechanical means by which we continue
to monitor and refine, it is the set of approaches we use to win hearts and minds, to make
people want to keep applying best practice in shop organization and housekeeping.
In this sense, discipline is perhaps an unfortunate term as it implies people forced to do
something, with consequent penalties if they do not.
The way in which management achieves this establishment of ongoing commitment within
the workforce depends, of course, on the culture already in place.
As with the adoption of kaizen (continuous
improvement) or quality circles we have to press the right buttons to stimulate people. If the
business has a history of treating people like cattle, giving no credence to their suggestions and
simply trying to improve performance by driving the workers ever harder, then enthusiasm for any
sort of initiative aimed at building a better environment is going to be hard to generate.
There are a number of elements to any ongoing improvement activity in any business. Which take
pre-eminence in a particular organization varies with the history and culture of that organization?
COMPANY PROFILE
Dabur India Limited is the fourth largest FMCG Company in India with interests in
Health care, Personal care and Food products. Building on a legacy of quality and experience
for over 100 years, today Dabur has a turnover of Rs.1232 Crore with powerful brands like
Dabur Amla, Dabur Chyawanprash, Vatika, and Hajmola & Real.
The story of Dabur began with a small, but visionary endeavor by Dr. S. K. Burman,
a physician tucked away in Bengal. His mission was to provide effective and affordable cure for
ordinary people in far-flung villages. With missionary zeal and fervor, Dr. Burman undertook
the task of preparing natural cures for the killer diseases of those days, like cholera, malaria and
plague.
Soon the news of his medicines traveled, and he came to be known as the trusted 'Daktar'
or Doctor who came up with effective cures. And that is how his venture Dabur got its name -
derived from the Devanagri rendition of Daktar Burman. Dr. Burman set up Dabur in 1884 to
produce and dispense Ayurvedic medicines. Reaching out to a wide mass of people who had no
access to proper treatment. Dr. S. K. Burman's commitment and ceaseless efforts resulted in the
company growing from a fledgling medicine manufacturer in a small Calcutta house, to a
household name that at once evokes trust and reliability.
Dabur identifies nature-based Ayurvedic medicines as its area of specialization. It is the first
Company to provide health care through scientifically tested and automated production of
formulations based on our traditional science.
Dabur introduces Indian consumers to personal care through Ayurveda, with the launch of
Dabur Amla Hair Oil. So popular is the product that it becomes the largest selling hair oil brand
in India.
Widening the popularity and usage of traditional Ayurvedic products continues. The
ancient restorative Chyawanprash is launched in packaged form, and becomes the first
branded Chyawanprash in India.
Addressing rural markets where homemade oral care is more popular than multinational
brands, Dabur introduces Lal Dant Manjan. With this a conveniently packaged herbal
toothpowder is made available at affordable costs to the masses.
Dabur identifies nature-based Ayurvedic medicines as its area of specialization. It is the first
Company to provide health care through scientifically tested and automated production of
formulations based on our traditional science.
1930 – Automation and up gradation of Ayurvedic products manufacturing initiated
Widening the popularity and usage of traditional Ayurvedic products continues. The
ancient restorative Chyawanprash is launched in packaged form, and becomes the first
branded Chyawanprash in India.
Addressing rural markets where homemade oral care is more popular than multinational
brands, Dabur introduces Lal Dant Manjan. With this a conveniently packaged herbal
toothpowder is made available at affordable costs to the masses.
Dabur continues to make innovative products based on traditional formulations that can provide
holistic care in our daily life. An Ayurvedic medicine used as a digestive aid is branded and
launched as the popular Hajmola tablet.
1979 - Commercial production starts at Sahibabad (U.P.), the most modern herbal
medicines plant at that time
The Ayurvedic digestive formulation is converted into children's fun product with the launch of
Hajmola Candy. In an innovative move, a curative product is converted to a confectionery item
for wider usage.
Dabur establishes its leadership in health care as one of only two companies worldwide to
launch the anti-cancer drug Intaxel (Paclitaxel). Dabur Research Foundation develops an
Eco-friendly process to extract the drug from its plant source
1996 - Enters foods business with the launch of Real Fruit Juice
Dabur establishes its market leadership status by staging a turnover of Rs.1000 corers. Across a span
of over 100 years, Dabur has grown from a small beginning based on traditional health care. To a
commanding position amongst an august league of large corporate businesses.
with the setting up of Dabur Oncology's sterile cytotoxic facility, the Company gains entry into
the highly specialized area of cancer therapy. The state-of-the-art plant and laboratory in the UK
have approval from the MCA of UK. They follow FDA guidelines for production of drugs
specifically for European and American markets.
2002 - Dabur record sales of Rs 1163.19 crore on a net profit of Rs 64.4 crore
CORE VALUES
Ownership: This is our company. We accept personal responsibility, and accountability to
meet business needs.
Passion for Winning: We all are leaders in our area of responsibility, with a deep
commitment to deliver results. We are determined to be the best at doing what matters most.
People Development: People are our most important asset. We add value through result
driven training, and we encourage & reward excellence.
Consumer Focus: We have superior understanding of consumer needs and develop products to
fulfill them better.
Team Work: We work together on the principle of mutual trust & transparency in a boundary-less
organization. We are intellectually honest in advocating proposals, including recognizing risks
Innovation: Continuous innovation in products & processes is the basis of our success
Integrity: We are committed to the achievement of business success with integrity. We are honest
with consumers, with business partners and with each other
DABUR AT A GLANCE
Dabur India Limited has marked its presence with some very significant achievements and
today commands a market leadership status. Our story of success is based on dedication to nature,
corporate and process hygiene, dynamic leadership and commitment to our partners and
stakeholders.
Strategic positioning of Honey as food product, leading to market leadership (over 40%) in
nd
branded honey HCPD, dealing with daily health care, 2 largest SBU with 28% share in Products
related to Health Supplements, Digestives, Baby Care and Natural Cures.
Leadership in Ayurvedic and herbal products market with highly popular brands.
Dabur Chyawanprash the largest selling Ayurvedic medicine with 65% (Rs.127 crore) market
share.
Charted high growth with 15% in 2001.
Dabur Chyawanprash and Hajmola account for sales of over Rs.100 crore each.
Leader in herbal digestives with 90% market share.
Hajmola tablets in command with 75% market share of digestive tablets category
sales.
CHAPTER - 3
In Dabur India Ltd., Sahibabad. Need based system of importing training is followed.
Training is based on the frequency of defects found during the production. Job supervisor is
vigilantly watching each and every product. If he find any defect in the product, he instructs the
worker to do right way. If no. of worker are doing same mistake, than all of them are taken in a
group and provided training spontaneously & the process in reurded. This way only defective
based training is provided by the company.
CHAPTER - 4
Analysis of responses
Dabur basically provides three types of training to its staffs. These training programs are:
1. Skill Enhancement
2. Personality enhancement
3. IT Related
20%
IT Related
40%
Personality
Enhancement
Skill Enhancement
40%
Out of the 20 staffs only 8 underwent the IT related training program. 8 got the training in
personality enhancement. And 14 got skill enhancement training. It exhibits that most of them
had all the three training program, skill enhancement, personality development and IT related.
35%
Before the Training
In the analysis of the training program, the next question was, “when the study material should
be provided either before the training or after. Out of 20, 15 trainees opt that study material
should be given before the training. And just 5 want the study material to be provided after the
training.
Test Should Be
50% 50%
Test should not be
Before any training program should there be any test for the purpose of selection of the trainees.
Regarding this out of 20, 10 trainee’s replies in the favour of the test and 10 were against any
10%
20%
15%
Poor
Fair
Average
Good
55%
The competence of the training program well defined has been assessed on the basis
of certain qualities.
5%
25%
Fair
Average
Good
70%
On the aspect of gaining of new ideas in the training program, most of them found that, they
got new ideas. The no. of staffs that had this type of thought is 15. Out of 20, 15 trainees
think that new ideas gaining through the program was average. Just one person thought
Self-Development
5% 5%
Poor
30%
Fair
Average
45%
Good
Outstanding
15%
Out of 20%, I thinks that training is poor, 6 thinks training is fair, for 3 training is
idea in the training program, it was found that out of 20 trainees 10 thinks, that while training
program what-ever they got was relevant the current job. Rest 10 thinks that the program is not
related of current job. This will be very helpful in the future to perform their job in a better
way.
5%
15%
25% Poor
Fair
Average
Good
40% Outstanding
20%
Efficient use of time in the training program is very much important for every worker or staff,
15%
20%
Fair
Average
Good
25% Outstanding
40%
Maintaining the interest of participants is essential for the success of any program. It was found
that no one says that he didn’t have any interest in the training program. Out of 20, 7 trainees
say that in the program their interest was good. Rest 13 says that, their interest in training
Clarity:
15%
10%
Poor
Fair
55%
Average
Good
30%
In any program, clarity is an important factor, without it we can’t assume the success of any
such program. The clarity of materials and lectures are very important in making the program
a successful event. 11, out of 20 trainees say that the program is very good on clarity. Rest 9
The training program has mainly been areas rated on three parameters.
i. Skill Enhancement
iii. IT Related
All the trainees have rated the training program differently on the basis of all the
three parameters.
Skill Enhancement:
5%
15%
Poor
Fair
Good
25%
Excellent
55%
According to the development of skills out of 20 trainees 11 have experienced good and 14
Personality Enhancement:
5%
10%
25%
Poor
Fair
Good
Excellent
60%
On the basis of personality enhancement 12, out of 20 trainees rated this training program
good and rest 13 rated this program average (poor, fair, excellent).
IT development:
20% 15%
Poor
Fair
20%
Good
Excellent
45%
staffs rated this training program good and rest 14 rated average (poor, fair, excellent).
5%
15%
50%
The experienced of the training program is so impressive that all the trainees very much
interested in these types of programs. They want more of such types of training programs. So
3, out of 24 trainees want this type of training in every month .On the other hand 10 trainees
want such program once in every three month. 6 out of them want to hold such types of program
twice in a year. Rest of them wants to hold this once a year. In my opinion it should be twice a
year.
4
10%
6
25%
8
65%
The duration of the training program is a big question for the management. All trainees who
had attended the training program have different thoughts about that. 2 out of 20 trainees want
the duration of these programs to be 8 hours. 13 of them want 6 hours and 2 want the duration
to be 4 hours.
Total 45 workers have gone through these training programs. 2 out of them got the skill
enhancement training, 4 got personality development, and 6 got skill enhancement &
personality development program. Out of 45 workers 8 got skill enhancement & IT related
training, 11 got personality development & IT related training and rest 14 got all three, skill
Improvement
Not Improvement
Can’t say
To read the development after applying development programs questions are asked to the
workers. Responding to the questions 16 out of 45 workers say that they go to improvement
after the training program, 15 told that they didn’t get any improvement and rest 14 are not
In any training program the material plays an important role. So it should be provided. But the
question is that, "when should be the materials be given, before the training or after the
Question, 30 out of 45 workers say that materials should be given before the training and 15
Ready to face
test
Don't ready to
face test
A good trainee is essential for the successful completion of any training program. A good
trainee can be selected by the test. So a test is required for selecting appropriate trainees.
Responding this 27 out of 45 workers tell that they don’t want to go through any test and rest
trainees.
Skill Enhancement:
Good
Very good
Excelent
Responding to skill enhancement programs, 11 out of 45 workers say that the training program
was good, 20 say that it ways very good and rest 14 trainees opine that training program was
very helpful to enhance their skills and perform their job in batter manner.
Personality Enhancement:
Good
Very good
Excelent
Responding to the personality development questions there are different views of the trainees,
6 out of 45 workers say that the program was good, 18 say that it was very good and 21 workers
IT related:
Good
Very good
Excelent
Responding to the IT related development questions trainees are very much conscious about
their improvement. 10 out of 45 have good experienced regarding IT development, 13 say that
program was very good and rest 22 have excellent experienced regarding IT in the training
program.
4 Hours
8 Hours
16 Hours
20 Hours
The duration is an important factor for the successful completion of any program. It should be
according the requirement of the trainees. 2 out of 45 trainees say that duration should be 4
hours, 6 say that duration can be 8 hours. 10 out of them want 16 hours and rest 27 wants 20
Every month
Once in 3
months
Once in 6
months
Once in every
year
Due to the changes in business the frequency of these types of training program should be
higher. It should be according to the convenience of trainees. 10 out of 45 want this program
should be conducted every month, 8 want after every three months but 20 thinks that the gap
between two programs should be exceed 6 months. Rest 16 wants the frequency of these
Suggestions
There is no gainsay regarding the training programs enhance the quality of the performance.
No one is perfect in his respective field. A full flazed training program makes trainees complete
Every company looks for a worker, who can work effectively. They are in search of a
person who has the maximum skills required for the job. After selecting the right person, the
company’s main aim is to make that person a perfect workman. For this they provide them
training.
First of all the management should look for that areas where workers needs training.
For this purpose management should keep eyes on each and every activity of the workers and
staffs whosoever may need training. This is a long and time taking process. In this way the next
step would be to select the trainees. There should develop a mechanism for selecting the
trainees. There should be a test for this purpose. This will give the idea about the weak and
strong points of trainees. It will be very fruitful in designing the contents of training program.
The printed material is very useful in training. These materials should be given before
the training. Written material would provide the overall idea about the training and make the
Before developing the training contents some points should be taken care of. There
should be some practical values in that. The training should include new ideas and should be
helpful in the development of trainees. It must be relevant to the hob of workers and staffs. In
the training process the efficient use of time should be made as time is the most important factor
in any job.
The frequency of training program is according to the requirement and convenience of
the trainees as well as the management. Workers require more training so they need one in
every six month. Staffs required less training in the compression of workers, so they required
The duration of any event is the most important, which maker any program successful
or fail. It should be according to the needs of the trainees of participants. In my opinion the
LIMITATIONS
Training is a costly affair for the management. It needs a handsome amount and long
time. So management has to play safe game for the benefits of the company as well as the
workers. One wrong decision may enforce the company to fall into deep troubles. So selecting
the weak areas of staffs and workers should be done very carefully. For that the management
Selecting a particular trainer is again a difficult job. Trainer demands handsome money.
To conclude, it is very clear that training should be provided but not at the loss of the
company. It is very costly and time taking affair. But it is most important for the development
ANNEXURE
(QUESTIONNAIRE)
Name …………………………………………………
Department ………………………………………
Designation ………………………………………
Skill Enhancement
Personality Enhancement
IT Related
2. Please indicate when should the study material be given to the trainees?
Yes
No
6. In your opinion what should be the frequency of the training programme in your
company.
Once in a month
Once in 6 month
Once in 12 month
_____________________________________________________
Date: Signature