MOLD, MOULD MANUFACTURING LTD.

Lack of skilled or trained employees is a huge obstacle to business growth at many plastics processing companies. How bad is it? One molder noted recently to the author that they've had 30 positions open for nearly six months, but have been unable to fill them. As a result, many molders are implementing training programs of their own, which PlasticsToday has written about several times in previous articles.

Now, Andy Routsis, president of Routsis Training, has launched his new RightStart program to help plastics companies accelerate training initiatives. Built on 30 years of plastics training, RightStart is customized to meet the specific training needs of each molder and its employees. "There's no such thing as a one size fits all when it comes to training, and this industry was crying out for something that meets the needs of individual companies," Routsis explained in an interview with PlasticsToday. "They don't want the same training as everyone else because situations are unique, and most molders what to train to their situation."

Routsis begins these customized programs with an on-site visit, and develops a training plan based on the company's needs. Using the "Blended Learning Model," Routsis training specialists select from a comprehensive array of world-class online courses and advanced process simulators products in collaboration with experts throughout the industry. "We write up detailed training plans for our customers, not just with our materials but if our customer buys robots or other equipment, we show them how to implement that into the training program as well."          

Routsis noted that his training business has grown tremendously over the past two years, primarily because molders have gotten much busier in 2010 and 2011. During the recession years of 2008 and 2009, many processors had to let employees go. And many older employees, who represent the knowledge base of these companies, have been retiring.

"Business picked up fairly quickly in 2010 and a lot of companies didn't plan for it," Routsis said. "Molders needed to hire trained and skilled employees, but they weren't available. Because of lack of training there were smashed molds and a lot of quality issues. It became a big problem. Some companies resorted to trying to hire talent by paying higher wages or stealing talent from other companies, but quite frankly the talent isn't there. They realized they need an ongoing training system in place."

The advantages of having an in-house online, ongoing, and hands-on training program, rather than sending employees offsite to a 14-day course, is that the online training is consistent and accessible anytime. Additionally, participants can go at their own pace, and what they learn is continuously reinforced through hands-on practice at the plant.

"They realize that training must be an ongoing process," said Routsis. "Companies that recognize this then need help in implementing an effective system. We put in complete systems, including how often to train and how to measure the benefit of that training. And RightStart offers direct applicability to their operation."

From the quantifiable side, Routsis Training establishes metrics and shows management what to look at so they can measure the progress of the employees from month-to-month. The RightStart online program is subscription based and employee-students gets up-to-date training materials such as "Establishing a Scientific Molding Process" and Material Drying which the company put out just eight weeks ago. The next one being released by Routsis Training is "Scientific Troubleshooting." The training materials are put into a dedicated training portal and management is then contacted by Routsis' trainers to tell them where to introduce the new program into their training.

"Management likes that we're always overseeing the activities of the employee-students," Routsis said. "We monitor the training activity and if training slows we notify management and tell them that training has slowed down so they can evaluate why that is."

Routsis products offer real-world learning that covers a variety of processes including injection molding, extrusion, blow molding and DECOUPLED MOLDINGSM, as well as part and mold design, machine maintenance and more.

Routsis said that his company is "exploding on the training side" and the new RightStart program has had "unbelievable acceptance" in the industry. "We're even starting the program for companies in other countries," he said. "This program has opened up eyes of a lot of management people to the need for the right type of training program customized to their needs."