NASG Apprenticeship Program Structure

Department of Labor Our program is a registered program with the U.S. Department of Labor Office of Apprenticeship. We are considered a “hybrid” program that uses competences and time to complete the program. The registration requires that standards be written and approved by the Department of Labor. Standards include a list of NIMS credentials to be obtained during the duration of the program (4 years – approx. 8000 hrs).

Department of Labor – cont. Standards also include a complete outline of the R.T.I. (Related Theory Instruction) to be completed during the duration of the program. (576 hours or 144 hours/year is the D.O.L. program minimum). We train a minimum of 5 hours/week for approximately 47 weeks a year yielding about 235 hours/year (940 hrs/program completion).

Outline of Related Theory Instruction Instruction based on information in: Precision Machining Technology Textbook 2nd Edition. Introduction to Machining Introduction to machining Careers in machining Workplace skills Measurement, Material and Safety Introduction to safety Measurement Systems and Machine Tool Math Overview Semi-Precision Measurement Precision Measurement Quality Assurance, Process Planning and Quality Control Metal Composition and Classification Heat Treatment of Metals Maintenance, Lubrication and Cutting Fluid Overview

Outline of Related Theory Instruction – cont. Instruction based on information in: Precision Machining Technology Textbook 2nd Edition. Job Planning, Benchwork, and Layout Understanding Drawings Layout Hand Tools Saws and Cutoff Machines Offhand Grinding Drilling, Threading, Tapping, and Reaming Drill Press Introduction to the Drill Press Tools, Toolholding, and Workholding for the Drill Press Drill Press Operations

Outline of Related Theory Instruction – cont. Instruction based on information in: Precision Machining Technology Textbook 2nd Edition. Turning Introduction to the Lathe Workholding and Toolholding Devices for the Lathe Machining Operations on the Lathe Manual Lathe Threading Taper Turning Milling Introduction to the Vertical Milling Machine Tools, Toolholding and Workholding for the Vertical Milling Machine Vertical Milling Machine Operations Indexing and Rotary Table Operations Grinding Introduction to Precision Grinding Machines Grinding Wheels for Precision Grinding Surface Grinding Operations

Outline of Related Theory Instruction Instruction based on information in: Basic Blueprint Reading and Sketching Textbook 9th Edition. Blueprint Reading Lines Views Dimensions and Notes The SI Metric System Sections Geometric Dimensioning and Tolerancing Working Drawings Technical Sketching Sketching Lines and Basic Forms Freehand Lettering Technical Sketching: Pictorial Drawings

Outline of Related Theory Instruction Instruction created at NASG to teach Die Construction and Maintenance. Types of Stamping Dies Station Dies Compound Dies Progressive Dies Transfer Dies Basic Die Construction Die Sets Guiding Components Punch Details Die Details Strippers Springs and Cylinders Stock Guides and Locators

Outline of Related Theory Instruction Instruction created at NASG to teach Die Construction and Maintenance. Types of Stamping Dies Station Dies Compound Dies Progressive Dies Transfer Dies Basic Die Construction Die Sets Guiding Components Punch Details Die Details Strippers Springs and Cylinders Stock Guides and Locators Fundamentals of Die Design Part Prints Bend Allowances Strip Layout Press Bed Layouts and Specifications Die Set Sizing Punches, Pilots and Retainers Die Sections, Buttons, Lifters, Stock Guides and Heel Blocks Cam Systems Shut Heights and Timing Strippers Maintenance Basic Sharpening Basic Form Timing Cutting Clearances Reading End Strips Troubleshooting Die Inspections

Department of Labor NIMS The Department of Labor “Rapids” website is used to report progress and make changes to apprentice status and pay. NIMS We work with the “National Institute for Metalworking Skills” (NIMS) to gain credentials that prove competencies during the term of the program. Competencies require classroom study, completion of a shop project and a theory test. Projects require inspection from an unbiased source (MET-TEC or T.S. / I.S.O Certified Quality Department. Tests are taken on-line and results are reported immediately. Credentials for the certified Tool and Die Maker Program include: Six machining Level I credentials Four machining Level II credentials Diemaking II Diemaking III

NASG Content Along with NIMS content NASG teaches other material designed to develop problem solving skills in apprentices. Examples of this are: Shop math and trigonometry every week throughout the program Blueprint reading and sketching using a textbook Mechanical drafting using a drafting board and instruments Basic 2D CAD classes (after basic drafting has been taught) Die type and construction practices Die design fundamentals Die maintenance Various shop projects that demonstrate different processes and leave the apprentice with tools that can be used throughout their career

Wonderlic Testing When we decided to add a new class to our program we desired to find an objective way to choose candidates from a pool of incumbent employees and from outside the company. We worked with Wonderlic to create a three part evaluation test for all candidates. The first part of the test is a timed test that measures cognitive ability, mechanical reasoning and abstract thinking. The second part of the test gauges the motivational potential of the candidates or “drivers’ as Wonderlic puts it. The third part of the test evaluates the candidates personality and how that personality would fit within a program such as ours. On March 1st of this year we started a new class populated with students that were chosen passed on this testing and the results are very encouraging. They appear to be very quick learners that display a desire to learn new things. They work extremely well together as a team.

Program Capacity NASG currently has 11 apprentices in the program. Apprentices are spread over three separate classes. All apprentices work at least five days a week on first shift. Each apprentice clocks out to train for 5 hours once day a week. Supervision in the shop is accomplished using two full time apprentice trainers in the early stages and then journey workers as apprentices develop. All classroom training is done by the training manager.

Capacity Constraints Access to shop equipment without interfering with production needs. Recurring access to a training room that is conducive to learning. Overloading the shop with under-skilled labor each time a new class forms. The length of the program (4 years).

Countermeasures Created a dedicated apprentice shop. Approximately 1,350 square feet of floor space. (2) New 14 x 40 Summit Lathes. (2) New 10 x 50 Summit Milling Machines. (2) New 6 x 18 Okamoto Surface Grinders. (2) New 20” Clausing Drill Presses. (2) Large Steel Work Tables (rated @15,000 lbs) with Wilton Vises and an Arbor Press. (2) 24 x 36 Surface Plates with Stands and with Height Gages and Indicators. (2) Baldor Bench Grinders and Stands. (2) Belt / Disc Sanding Machine. All necessary accessories for each machine (tool holders, adapters, chucks, drills, vises, clamp sets, angle plates, spin fixtures, etc).

Countermeasures Created a dedicated training room

Countermeasures Exploring ways to expedite the training / skills of beginning apprentices. Looking at possibility front loading some Related Theory Instruction to give apprentices usable skills quicker. Looking at programs offered at various technical schools to see if they can be of use to NASG. Taking steps to expand our program to our other divisions.

Grant Money We secured a $25,000 grant in 2016 through Workforce Essentials. Since then we have been unable to find any additional external funding. NIMS and Workforce Essentials both have grant money from the Department of Labor but we are being told it can only be used for apprenticeship startup.

Cost of Program Cost of New Shop and Training Room Payroll Costs $182,000 Payroll Costs Training Manager, 2 Trainers, 11 Apprentices. $1,032,739 Ongoing Costs Supplies, Occupancy, Depreciation, Equipment Maintenance, Management Oversight. $97,321 Total Ongoing Program Cost $1,130,060

NASG Apprenticeship Program Timeline of Program and Wage Scale Apprenticeship Year Apprentice Level Approximate Hours Required NIMS Credential Wage Per Scale YEAR 1 Level 1 0-1000 Measurement, Materials and Safety, Job Planning, Benchwork and Layout Level 2 1000-2000 Drill Press Skills YEAR 2 Level 3 2000-3000 Manual Milling Skills 1 Grinding Skills 1 Level 4 3000-4000 Turning Operations: Turning / Chucking 1 YEAR 3 Level 5 4000-5000 Manual Milling Skills 2 Surface Grinding Skills Level 6 5000-6000 Turning Operations: Turning / Chucking 2 Cylindrical Grinding Skills YEAR 4 Level 7 6000-7000 Die Making Level 2 Level 8 7000-8000 Die Making Level 3 Level 8 Plus Six Months Probationary Period