SkillsMatrix - Operator Competency Tracking

Purpose: Track who can run what, plan training, ensure coverage, support IATF 16949 compliance.

When to Activate

• "Who can run the NLX2500?"
• "Create training matrix"
• "What machines is Dave trained on?"
• "Do we have backup for Swiss?"
• "Training needs for new hire"
• "Competency gap analysis"

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IATF 16949 Requirements

Clause 7.2 - Competence

The organization shall determine necessary competence, ensure competence based on education/training/experience, take actions to acquire competence, and retain documented evidence.

Required Documentation

1. Competency definitions - What skills needed per role
2. Training records - Evidence of training completed
3. Competency assessment - Verification of capability
4. Ongoing effectiveness - Periodic revalidation

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Competency Levels

| Level | Code | Description | Can Do | |-------|------|-------------|--------| | Not Trained | 0 | No exposure | Nothing | | Awareness | 1 | Observed, understands basics | Assist only | | Under Training | 2 | In training program | Supervised work | | Competent | 3 | Can work independently | Standard work | | Proficient | 4 | Handles complex jobs | All work + troubleshoot | | Expert | 5 | Trains others, process owner | All + train + improve |

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Skills Matrix Template

By Machine

# MNMUK Skills Matrix - Machines

Last Updated: YYYY-MM-DD

| Employee | NMV3000 | DMU50 | NHX500 | VMC 4-Axis | NLX2500 Twin | NLX2500 Single | ALX2000 | HARDINGE | CITIZEN Laser | CITIZEN LFV | Wire EDM | Spark EDM | Haas Mill | Haas Lathe |
|----------|---------|-------|--------|------------|--------------|----------------|---------|----------|---------------|-------------|----------|-----------|-----------|------------|
| [Name 1] | | | | | | | | | | | | | | |
| [Name 2] | | | | | | | | | | | | | | |
| [Name 3] | | | | | | | | | | | | | | |

**Legend:** 0=Not Trained, 1=Awareness, 2=Under Training, 3=Competent, 4=Proficient, 5=Expert

By Skill Category

# MNMUK Skills Matrix - Categories

| Employee | 5-Axis Mill | 4-Axis Mill | CNC Turning | Swiss | EDM | Setup | Programming | Quality/Inspection | First-Off | Forklift | Crane |
|----------|-------------|-------------|-------------|-------|-----|-------|-------------|-------------------|-----------|----------|-------|
| [Name] | | | | | | | | | | | |

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Machine-Specific Requirements

DMG MORI 5-Axis (NMV3000, DMU50, NHX500)

Required Competencies:

• [ ] CELOS interface operation
• [ ] 5-axis work coordinate setup
• [ ] Pallet system operation (NMV3000/DMU50)
• [ ] Tool length measurement
• [ ] Probe calibration and use
• [ ] Crash recovery procedures
• [ ] Program editing (basic)

Training Hours: 40-80 hours supervised Certification: Internal practical assessment

DMG MORI Turning (NLX2500, ALX2000)

Required Competencies:

• [ ] Chuck/collet setup
• [ ] Bar feeder operation
• [ ] Live tooling setup
• [ ] Sub-spindle transfer (NLX2500)
• [ ] Tool offset adjustment
• [ ] In-process gauging
• [ ] Chip management

Training Hours: 30-60 hours supervised Certification: Internal practical assessment

HARDINGE Precision Turning

Required Competencies:

• [ ] All standard turning competencies
• [ ] Precision setup techniques
• [ ] Temperature compensation understanding
• [ ] Micro-adjustment of offsets
• [ ] SPC/gauging for tight tolerances

Training Hours: 60-100 hours supervised (after CNC turning base) Certification: Practical assessment on ±0.003mm parts

CITIZEN Swiss (Laser Head, LFV)

Required Competencies:

• [ ] Guide bushing selection and setup
• [ ] Gang tooling setup
• [ ] Sub-spindle pickup programming
• [ ] Oil system management
• [ ] LFV parameter adjustment (LFV model)
• [ ] Laser operation (Laser model)
• [ ] Small part handling

Training Hours: 80-120 hours supervised Certification: Manufacturer training recommended + internal

MITSUBISHI EDM (Wire & Spark)

Wire EDM Competencies:

• [ ] Wire threading (auto and manual)
• [ ] Start hole location
• [ ] Multi-pass programming understanding
• [ ] Flushing optimization
• [ ] Wire break recovery

Spark EDM Competencies:

• [ ] Electrode design principles
• [ ] Electrode alignment
• [ ] Orbiting parameters
• [ ] Surface finish control

Training Hours: 40-80 hours per machine type Certification: Internal assessment

Haas Fast Response

Required Competencies:

• [ ] Basic Haas control operation
• [ ] Manual tool setting
• [ ] Vice setup and alignment
• [ ] G-code basics
• [ ] When to escalate to production machines

Training Hours: 16-24 hours (entry level machine) Certification: Internal practical

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Training Record Template

# Training Record

## Employee Information
| Field | Value |
|-------|-------|
| Name | |
| Employee ID | |
| Start Date | |
| Department | |
| Role | |

## Training History

| Date | Training | Machine/Skill | Trainer | Hours | Assessment | Result | Next Review |
|------|----------|---------------|---------|-------|------------|--------|-------------|
| | | | | | | | |

## Current Competencies

| Machine/Skill | Level | Date Achieved | Assessor | Evidence |
|---------------|-------|---------------|----------|----------|
| | | | | |

## Training Plan

| Skill Needed | Target Level | Target Date | Training Method | Progress |
|--------------|--------------|-------------|-----------------|----------|
| | | | | |

## Signatures

| Role | Name | Signature | Date |
|------|------|-----------|------|
| Employee | | | |
| Supervisor | | | |
| Training Coordinator | | | |

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Coverage Analysis

Minimum Coverage Requirements

| Machine Type | Min Operators | Current | Gap | Risk Level | |--------------|---------------|---------|-----|------------| | 5-Axis Mills | 3 | | | | | 4-Axis VMC | 2 | | | | | NLX2500 Turning | 3 | | | | | HARDINGE | 2 | | | | | CITIZEN Swiss | 2 | | | | | Wire EDM | 2 | | | | | Spark EDM | 1 | | | | | Haas (any) | 2 | | | |

Risk Assessment

| Risk Level | Coverage | Action | |------------|----------|--------| | Critical | 0-1 operators | Immediate training required | | High | 2 operators | Cross-train within 3 months | | Medium | 3 operators | Maintain, develop experts | | Low | 4+ operators | Focus on specialization |

Single Point of Failure Report

# Single Points of Failure

Machines with only ONE competent operator:

| Machine | Only Operator | Risk | Mitigation Plan |
|---------|---------------|------|-----------------|
| | | | |

Action Required: Cross-train second operator within [X] weeks

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Training Needs Analysis

New Hire Onboarding

Week 1-2: Orientation

• [ ] Safety training
• [ ] Quality system overview
• [ ] Shop floor familiarization
• [ ] Basic measurement tools

Week 3-4: Foundation

• [ ] Haas Mini Mill basics
• [ ] Blueprint reading
• [ ] GD&T fundamentals
• [ ] First-off inspection

Month 2-3: Primary Machine

• [ ] Assigned machine training
• [ ] Supervised operation
• [ ] Progressive independence

Month 4-6: Competency

• [ ] Independent operation
• [ ] Formal assessment
• [ ] Sign-off to Level 3

Cross-Training Priority

# Cross-Training Priority Matrix

Based on: Coverage gaps, business risk, employee development

| Priority | From Machine | To Machine | Candidate | Reason |
|----------|--------------|------------|-----------|--------|
| 1 | | | | Coverage gap |
| 2 | | | | Backup needed |
| 3 | | | | Development |

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Competency Assessment Checklist

Practical Assessment Template

# Competency Assessment

**Employee:**
**Machine:**
**Date:**
**Assessor:**

## Setup Assessment
| Task | Pass | Fail | Notes |
|------|------|------|-------|
| Interpret setup sheet | | | |
| Select correct tooling | | | |
| Install workholding | | | |
| Set work offsets | | | |
| Verify tool offsets | | | |
| Load program correctly | | | |

## Operation Assessment
| Task | Pass | Fail | Notes |
|------|------|------|-------|
| Start machine safely | | | |
| Run first part at reduced feed | | | |
| Monitor cutting conditions | | | |
| Respond to abnormal conditions | | | |
| Adjust offsets correctly | | | |
| Maintain quality during run | | | |

## Quality Assessment
| Task | Pass | Fail | Notes |
|------|------|------|-------|
| Perform first-off inspection | | | |
| Use measurement equipment correctly | | | |
| Record results properly | | | |
| Identify out-of-spec conditions | | | |
| Know when to stop and escalate | | | |

## Safety Assessment
| Task | Pass | Fail | Notes |
|------|------|------|-------|
| PPE compliance | | | |
| Guards in place before start | | | |
| Emergency stop knowledge | | | |
| Chip/coolant handling | | | |
| Housekeeping | | | |

## Result

| | |
|---|---|
| Total Pass: | /20 |
| Assessment Result: | PASS / FAIL |
| Competency Level Awarded: | |
| Retest Required: | Y / N |
| Retest Date: | |

**Assessor Signature:** _________________ **Date:** _________
**Employee Signature:** _________________ **Date:** _________

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Reports

Monthly Skills Report

# Skills Matrix Report - [Month YYYY]

## Coverage Summary
| Machine Category | Required | Available | Gap | Status |
|------------------|----------|-----------|-----|--------|
| 5-Axis | 3 | | | |
| Turning | 3 | | | |
| Swiss | 2 | | | |
| EDM | 2 | | | |

## Training Completed This Month
| Employee | Training | New Level |
|----------|----------|-----------|
| | | |

## Training In Progress
| Employee | Training | Target Date | % Complete |
|----------|----------|-------------|------------|
| | | | |

## Upcoming Training Needs
| Employee | Training | Start Date | Reason |
|----------|----------|------------|--------|
| | | | |

## Actions Required
1.
2.
3.

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Integration

• CNCSetup: Only generate setup sheets for machines operator is trained on
• PlantCapability: Consider operator availability in machine selection
• TribalKnowledge: Experts (Level 5) are primary knowledge sources
• AutomotiveManufacturing: Supports IATF 16949 Clause 7.2 compliance