Course Title:

Floor Management, Safety, Compliance and Responsibility

Course Duration:

• Total Duration: 5 Days
• Daily Duration: 6 hours per day
• Format: Combination of lectures, hands-on training, practical demonstrations, and assessments

Course Objectives:

• Understand the roles and responsibilities of workers and machine operators in a flexible packaging factory.
• Develop skills in operating and maintaining packaging machinery.
• Learn best practices for safety, efficiency, and quality in the production process.
• Gain knowledge of common issues and troubleshooting techniques.
• Foster teamwork and communication among factory staff.

Target Audience:

• Machine operators and technicians in the flexible packaging industry.
• Production line workers.
• Maintenance personnel.
• New hires and existing employees needing refresher training.

Day 1: Introduction to Flexible Packaging Production and Worker Roles

1. Overview of Flexible Packaging Production:

   • Introduction to the flexible packaging industry.
   • Overview of production processes (extrusion, printing, laminating, slitting, etc.)
   • Importance of worker and machine operator roles in production efficiency.

2. Roles and Responsibilities of Workers:

   • Understanding different roles on the production floor.
   • Coordination between machine operators, technicians, and other workers.
   • Expectations and responsibilities in maintaining production flow.

3. Workplace Safety and Compliance:

   • Safety protocols and procedures.
   • Personal protective equipment (PPE) and its proper use.
   • Compliance with industry regulations and workplace policies.

4. Case Studies:

   • Real-world examples of effective worker roles and safety practices.
   • Discussion on common challenges and solutions.

Day 2: Machine Operation and Maintenance

1. Introduction to Packaging Machinery:

   • Overview of common machinery used in flexible packaging (extruders, printers, laminators, slitters, etc.)
   • Understanding machine functions and capabilities.
   • Basic machine setup and operation.

2. Machine Maintenance Basics:

   • Importance of regular maintenance for optimal machine performance.
   • Routine checks and preventive maintenance tasks.
   • Lubrication, cleaning, and calibration procedures.

3. Troubleshooting Common Machine Issues:

   • Identifying common machine problems (jams, misalignment, material feed issues, etc.)
   • Step-by-step troubleshooting techniques.
   • When to escalate issues to maintenance or technical teams.

4. Hands-On Training:

   • Practical exercises in machine operation and maintenance.
   • Simulated troubleshooting scenarios.

Day 3: Quality Control and Efficiency in Production

1. Understanding Quality Standards:

   • Importance of quality in flexible packaging production.
   • Overview of quality control processes and standards.
   • Role of workers and machine operators in ensuring product quality.

2. Process Monitoring and Adjustments:

   • Techniques for monitoring production processes.
   • Making adjustments to machinery settings to maintain quality.
   • Recording and reporting quality data.

3. Lean Manufacturing Principles:

   • Introduction to lean manufacturing and waste reduction.
   • Techniques for improving efficiency on the production floor.
   • Role of workers in continuous improvement initiatives.

4. Case Studies and Practical Exercises:

   • Examples of quality control and efficiency improvements.
   • Hands-on exercises in process monitoring and adjustments.

Day 4: Advanced Machine Operation and Teamwork

1. Advanced Machine Techniques:

   • Operating complex machinery and multi-stage processes.
   • Understanding advanced machine settings and controls.
   • Optimizing machine performance for different packaging materials.

2. Teamwork and Communication:

   • Importance of teamwork on the production floor.
   • Effective communication between machine operators, workers, and supervisors.
   • Conflict resolution and problem-solving techniques.

3. Emergency Procedures and Problem-Solving:

   • Handling emergency situations (machine breakdowns, safety incidents, etc.)
   • Step-by-step emergency protocols.
   • Role-playing exercises in problem-solving and teamwork.

4. Group Projects and Presentations:

   • Team-based projects focusing on improving machine operation or production efficiency.
   • Presentations and discussions of project outcomes.

Day 5: Course Review, Assessment, and Certification

1. Review of Key Concepts:

   • Recap of essential skills and knowledge covered in the course.
   • Group discussion on challenges faced during training.

2. Assessment and Practical Evaluation:

   • Written and practical assessments to test participants’ understanding and skills.
   • Hands-on evaluation of machine operation and maintenance.

3. Q&A and Feedback Session:

   • Open forum for participants to ask questions and discuss any remaining doubts.
   • Collection of feedback for course improvement.

4. Certification Ceremony:

   • Awarding certificates to participants who successfully complete the course.
   • Final remarks and course wrap-up.

Course Materials:

• Training manual with detailed instructions and guidelines.
• Machinery operation and maintenance checklists.
• Safety protocol handouts.
• Case study documents.
• Assessment and feedback forms.

Evaluation and Feedback:

• Daily practical evaluations and quizzes.
• Final written and practical assessment.
• Participant feedback forms for continuous improvement of the course.

This course structure is designed to provide comprehensive training to workers and machine operators in a flexible packaging factory, focusing on operational efficiency, safety, and teamwork.