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"

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

• Competency definitions - What skills needed per role

• Training records - Evidence of training completed

• Competency assessment - Verification of capability

• Ongoing effectiveness - Periodic revalidation

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

Skills Matrix Template

By Machine

MNMUK Skills Matrix - Machines

Last Updated: YYYY-MM-DD

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

By Skill Category

MNMUK Skills Matrix - Categories

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

Training Record Template

Training Record

Employee Information

Training History

Current Competencies

Training Plan

Signatures

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:

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

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

Competency Assessment Checklist

Practical Assessment Template

Competency Assessment

Employee: Machine: Date: Assessor:

Setup Assessment

Operation Assessment

Quality Assessment

Safety Assessment

Result

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

Reports

Monthly Skills Report

Skills Matrix Report - [Month YYYY]

Coverage Summary

Training Completed This Month

Training In Progress

Upcoming Training Needs

Actions Required

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