proposed training project details training proposal … zodiac proposal with attach.pdf · proposed...

PROPOSED TRAINING PROJECT DETAILS

Training Proposal for C&D Zodiac: 17-0621 of 7

TRAINING PROPOSAL FOR

C&D Zodiac, Inc.

17-0621

Panel Meeting Date: 08/25/2017

Regional Office: San Diego Regional Office

Analyst Name: Davey, Joe

Type of Proposal: Single Employer Contract (SE)

Funding Source: Out-of-State Competition

FUNDING OVERVIEW

Provided here is a summary of the funding for the proposed Training Project.

TOTAL ETP FUNDING: $626,778

Program & Admin Cost Support Cost Substantial Contribution

(50%/15%) Total In-Kind

$739,350.00 N/A $112,572 $765,000.000

APPLICANT PROFILE

Company Summary

C&D ZODIAC, INC., (Zodiac), (http://www.zodiacaerospace.com) designs and manufactures aircraft interior components, such as overhead bins, cabinets, galleys, lighting, stairways and doors. Zodiac and its sister company, Driessen Aircraft Interior Systems, will participate in this project together. Both companies are owned by Zodiac Aerospace of France.

Industry Sector(s) Manufacturing

Priority Industry Yes

No. of Employees (Applicant) State: 3,600 US: 5,700 World Wide: 32,388

Turnover Rate (Applicant) 5.00%

Repeat Contractor Yes

High Unemployment Area No

Unions N/A



TRAINING PROFILE

Training Objective

C&D Zodiac will provide training to its employees at nine California locations in necessary skills required to improve efficiency and productivity.

Training is summarized below. Additional details are provided in Attachment 1 - Group and Job Title Details of this Panel Proposal.

# Group Characteristics # of Trainees

Reimbursement Rate

Avg. Hours

Cost Per Trainee

Min – Max Hour

1 Retrainees 775 $18.00 53 $954.00 8-200



Provided here are the details on the proposed Training Project.

1. Company Background

Founded in 1972 and headquartered in Huntington Beach, Zodiac designs and manufactures aircraft interior components, such as overhead bins, cabinets, galleys, lighting, stairways and doors. C&D Zodiac, Inc. and its sister company, Driessen Aircraft Interior Systems, will participate in this project together. Both companies are owned by Zodiac Aerospace of France. Training will be conducted at the following location(s): Cypress, Garden Grove, Huntington Beach, Ontario, Rancho Cucamonga.

2. Current Training Project Details

Provided here are details on the purpose of the training, a summary of the marketing plan and support costs.

Purpose of Training

This will be Zodiac’s fifth ETP Agreement, fourth in the last five years. The previous Agreements (ET13-0236 and ET11-0199) focused on new design and engineering processes that occurred in advance of production to improve overall efficiency; reduce cost; and retain product quality. In its most recent Agreement (ET15-0424), much of the training was focused on Manufacturing Skills for employees in composite plastic and injection-mold manufacturing techniques. This proposal will continue training from the previous Agreement, with a focus on production efficiency. Training will not be duplicated. Zodiac’s two largest customers are increasing the production rate of new narrow-body airplanes, from 42 to 57 planes per month. This requires Zodiac to also increase production. In addition, as Zodiac expands into other markets, employees will need to be trained in how to reconfigure seats, overhead bins, and other aircraft interior components. Reconfiguring will change production specifications for both engineers and production workers.

Training Infrastructure and Administrative Plan

Zodiac retained National Training Company, Inc. to assist with project administration. In addition, the Company has designated internal staff to schedule and oversee training as well as collect and submit training rosters.

Marketing Plan (MEC Only)

N/A

Support Cost Description (MEC Only)

N/A

Substantial Contribution Description

C&D ZODIAC, INC. is a repeat contractor with payment earned in excess of $250,000 for incumbent workers at the locations below within the past five years. In its most recent Agreement, (ET15-0424), Zodiac was assessed a 30% substantial contribution for past earnings in excess of $250k for incumbent workers, most of whom were located at the Huntington Beach facility. Under this proposal, the new ETMS cost structure allows for the identification and assessment of each facility by location. Therefore, facilities will be assessed the respective substantial contribution based on prior (and projected) earnings for incumbent workers. Accordingly, reimbursement for trainees at these locations will be reduced as shown in the table below to reflect the Company’s Substantial Contribution to the cost of training.



Location Substantial Contribution

Level Of Reduction

C&D ZODIAC, INC. $95,400.00 50.00%

Garden Grove-Lincoln $5,724.00 15.00%

La Palma $11,448.00 15.00%

Ontario-Grove $0.00 0.00%

Ontario-Quaker Ridge $0.00 0.00%

Rancho Cucamonga $0.00 0.00%

Cypress $0.00 0.00%

Garden Grove-Industry $0.00 0.00%

Driessen Aircraft Interior Systems, Inc.

$0.00 0.00%

3. Sample Curriculum

Provided below is a summary of the methods by which training will be delivered including a sample of the courses that will be offered.

Each of the Trainee groups will be able to take courses under the various delivery methods.

Delivery Method/Level Classroom/Simulated Laboratory

Training Type/Level Sample Classes

Business Skills Business Processes & Performance

Effective Communication Skills

Project Management

Computer Skills Advanced Computer-Aided Design

Engineering Applications

Manufacturing Resource Planning software

Continuous Improvement C&D Quality Systems

Root Cause Analysis

Operating Procedures

Manufacturing Skills Component Fabrication

Design Standards & Processes

Tools & Processes

Hazardous Materials Hazardous Material Handling (non-certified)

Material Safety Data Sheets (MSDS) Procedures

HAZMAT



Delivery Method/Level Productive Laboratory (PL)

Training Type/Level Sample Classes Standard Hours

Productive Lab Component Fabrication Equipment 8-30

Component Forming Equipment 8-30

Plastic Injection Molding Equipment 8-30

Plastic Thermoforming Equipment 8-30

PL Details

Percentage of Curriculum that is Productive Lab: 5%

4. Additional Company or Training Project Details – Keep all subparagraphs

Provided here is additional information relative to the proposed Training Project.

4.1 Program Justifications

The next table lists the various waivers and supporting justifications for training that apply to this proposed Training Project.

Waivers/Justification Type Summary

Productive Laboratory Training Zodiac states that classroom instruction is an inadequate method of training on the Company’s proprietary thermo-forming and injection molding equipment. The most effective method of learning how to safely and efficiently operate these complex machines requires hands-on experience. Zodiac requests a maximum trainer-to-trainee ratio of 1:3. The company states that trainees work in small groups on the same product, and, to ensure consistent instruction, need to be trained together. Most of the PL training will be conducted 1:1, but in these infrequent cases, small group training is more effective and efficient. Trainees who are proficient on one type of equipment will be cross-trained on new equipment.

Type of Equipment Component Fabrication Equipment, Component Forming Equipment, Plastic Thermoforming Equipment, Plastic Injection Molding Equipment, Production Assembly and Repair Equipment

4.2 Subcontractor Summary

The applicant has retained the services of the following Subcontractor(s).

Subcontractor Type Subcontractor Name City Service Cost

Development National Training Company, Inc. Irvine $15,000

Administrative National Training Company, Inc. Irvine 13%

Training N/A $0.00



4.3 Previous ETP Project Summary - In this section the tables can be deleted if not needed

The table below summarizes the active performance under the ETP contract.

Active Contract(s) Elements

Summary

Agreement Number ET15-0424

Purpose of Training Company employees learned new manufacturing techniques and ways to reduce costs, improve product quality and improve on-time delivery.

Location(s) C&D Zodiac’s facilities in Los Angeles County (La Palma), Orange County (Huntington Beach, Garden Grove, Cypress); and San Bernardino County (Ontario (two locations) and Rancho Cucamonga.

Term 4/27/15 – 4/26/17

Approved Amount $306,060

Projected Earnings $306,060 $275,879 (incumbent)

Performance Percentage 100%

Other Notes ETP’s online tracking system shows 22,539 eligible training hours which is sufficient to support $284,644 (93%) in eligible earnings. The final closeout invoice is currently being processed by ETP.

This table summarizes Contractor's performance under prior contract(s) completed within the last five years.

Past Contract Activity

Agreement Number

Location(s) Term Approved Amount

Project Earnings Performance %

ET13-0236

Huntington Beach, Cypress, La Palma, Garden Grove, Ontario, Rancho Cucamonga, Santa Maria, Carlsbad

1/1/13 – 12/31/14

$447,750 $447,750 ($411,750 incumbent)

100% (92% incumbent)

ET11-0199

Huntington Beach, Cypress, La Palma, Garden Grove, Ontario, Rancho Cucamonga, Santa Maria, Carlsbad

4/11/11 – 4/10/13

$255,150 $86,776 34% (100% incumbent)

Notes ET11-0199 – C&D Zodiac’s second ETP project was Job Creation training for newly hired retrainees. Zodiac hired and trained more than 400 new employees. Despite providing more than 15,000 hours of training, very few of these trainees received the minimum 24 hours for full reimbursement due to internal difficulties in scheduling and maintaining rosters.



4.4 Supporting Panel Proposal Documentation

Provided in Attachments 1, 2 and 3 is additional application details on the intended training population, the detailed curriculum, and associated program characteristics that are related to this proposed Training Project.

Attachment 1 – Group and Job Title Details

Training Proposal for C&D Zodiac, Inc.: 17-0621 Attachment 1: Page 1 of 3

The proposed Training Project includes training for the following Trainees, organized by training group.

Group #: 1 – Retrainees

County ETP Minimum Wage

Los Angeles County $16.96

Orange County $17.22

San Bernardino County $16.16

Job Title Estimated Number of Trainees

Base Wage Range Health Benefits Applied

Post-Retention Wage

Los Angeles County

Administrative Staff 12 $12.86 - $21.17 $4.10 $16.96

Engineer 14 $23.64 - $35.66 $0.00 $23.64

Lead 10 $12.86 - $19.65 $4.10 $16.96

Managers/Supervisors 10 $20.27 - $43.35 $0.00 $20.27

Production Worker 20 $12.86 - $21.31 $4.10 $16.96

Technical Staff 14 $12.86 - $24.34 $4.10 $16.96

Orange County – 5701 Bolsa Ave, Huntington Beach


Engineer 35 $23.64 - $35.66 $0.00 $23.64

Lead 20 $13.12 - $19.65 $4.10 $17.22



Technical Staff 30 $13.12 - $24.34 $4.10 $17.22

Orange County – 11240 Warland Drive, Cypress


Engineer 15 $23.64 - $35.66 $0.00 $23.64

Lead 10 $13.12 - $19.65 $4.10 $17.22





Post-Retention Wage



Technical Staff 15 $13.12 - $24.34 $4.10 $17.22

Orange County – 12472 Industry Street, Garden Grove


Engineer 7 $23.64 - $35.66 $0.00 $23.64

Lead 5 $13.12 - $19.65 $4.10 $17.22



Technical Staff 7 $13.12 - $24.34 $4.10 $17.22

Orange County – 7330 Lincoln Way, Garden Grove


Engineer 7 $23.64 - $35.66 $0.00 $23.64

Lead 5 $13.12 - $19.65 $4.10 $17.22



Technical Staff 7 $13.12 - $24.34 $4.10 $17.22

Orange County – 17311 Nichols Lane, Huntington Beach


Engineer 14 $23.64 - $35.66 $0.00 $23.64

Lead 40 $13.12 - $19.65 $4.10 $17.22








Post-Retention Wage

San Bernardino County – 1945 S Grove Ave, Ontario


Engineer 4 $23.64 - $35.66 $0.00 $23.64

Lead 3 $12.06 - $19.65 $4.10 $16.16



Technical Staff 3 $12.06 - $24.34 $4.10 $16.16

San Bernardino – 1940 Quaker Ridge Place, Ontario


Engineer 4 $23.64 - $35.66 $0.00 $23.64

Lead 3 $12.06 - $19.65 $4.10 $16.16



Technical Staff 3 $12.06 - $24.34 $4.10 $16.16

San Bernardino - 11340 Jersey Blvd, Rancho Cucamonga


Engineer 2 $23.64 - $35.66 $0.00 $23.64

Lead 1 $12.06 - $19.65 $4.10 $16.16



Technical Staff 5 $12.06 - $24.34 $4.10 $16.16

Attachment 2 – Training Delivery and Curriculum Listing

Training Proposal for C&D Zodiac Inc:17-0621 Attachment 2: Page 1 of 2

Provided below are details on the types of training planned for this proposed Training Project.


Training Type/Level Planned Course Offerings

Business Skills Business Processes & Performance

Customer Service and Sales Skills

Effective Communication Skills

Project Management

Computer Skills

\ Advanced Computer-Aided Design

Compliance Training

Computerized Reports

Engineering Applications

Hardware and Software Systems Tools

Manufacturing Resource Planning Software

MS Office (Advanced)

MS Office (Intermediate)

Web-Based Computer Applications

Continuous Improvement

Best Manufacturing Practices

Boeing and Airbus Inspection Procedures

C&D Quality Systems

Increase Productivity

Operating Procedures

Root Cause Analysis

Standard Work Instructions

Team Building

Team Problem Solving

Waste Identification

Manufacturing Skills (Hazardous Materials)

Emergency Response Team Training

Hazardous Materials Handling (non-certified)

Hazardous Waste

HAZMAT Training

Material Safety Data Sheets (MSDS) Procedures

Manufacturing Skills

Component Fabrication

Critical Design Review

Attachment 2 – Training Delivery and Curriculum Listing




Cross-Functional Production Equipment Training

Design Standards and Processes

Engineering & Design Procedures

Forklift Procedures

Lean Manufacturing

Manufacturing Technologies

Overhead Bins

Plastic Injection Molding

Plastic Thermoforming

Practices & Procedures

Product Design & Development

Quality Control

Reading Technical Specifications

Standard Operating Procedures

Tools & Processes

Delivery Method/Level Productive Lab (PL)


Manufacturing Skills

Component Fabrication Equipment

Component Forming Equipment

Plastic Injection Molding Equipment

Plastic Thermoforming Equipment

Production Assembly and Repair Equipment

PL Justification and Details

Explain the need for productive laboratory (PL) training.

Classroom instruction is not an adequate means of training delivery because trainees must learn to operate proprietary equipment that requires hands on experience. The equipment is too large to bring into a classroom. Trainees who are proficient on one type of equipment will be cross-trained on new equipment. New hires will be trained on this equipment.

Describe the equipment/processes to be used in delivering PL training:

Component Fabrication Equipment, Component Forming Equipment, Plastic Thermoforming Equipment, Plastic Injection Molding Equipment, Production Assembly and Repair Equipment

Describe Trainer Qualifications:

Trainers will have at least 2 year of experience operating equipment before training others.

Attachment 3 - Training Project Characteristics Details


Provided in the table are details on the training characteristics.

Characteristic Program Summary

None Standard retrainee program with no additional characteristics.

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