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

| 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] | | | | | | | | | | | |

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
| 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 | | | |

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

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 |

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:** _________

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.

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

Skillsmatrix

SkillsMatrix - Operator Competency Tracking

When to Activate

IATF 16949 Requirements

Clause 7.2 - Competence

Required Documentation

Competency Levels

Skills Matrix Template

By Machine

By Skill Category

Machine-Specific Requirements

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

DMG MORI Turning (NLX2500, ALX2000)

HARDINGE Precision Turning

CITIZEN Swiss (Laser Head, LFV)

MITSUBISHI EDM (Wire & Spark)

Haas Fast Response

Training Record Template

Coverage Analysis

Minimum Coverage Requirements

Risk Assessment

Single Point of Failure Report

Training Needs Analysis

New Hire Onboarding

Cross-Training Priority

Competency Assessment Checklist

Practical Assessment Template

Reports

Monthly Skills Report

Integration