Training programs are conducted to enhance staff performance

Safar Mohammad Khan

Deputy General Manager-HDD

Apollo Techno Industries Pvt. Ltd.

There is a growing demand for newer and broader skill sets at different levels driven by surging demand and technology updation. How has your organization overcome these challenges in the assembly line / shop floor?

We resource the manpower through industry reference like Horizontal Directional Drilling industry. Our main criterion is to select the candidate from the mechanical cum electrical engineering background having some practical exposure. We gauge their skill through written and one-on-one interviews. To broaden the skill set of our manpower, we provide them appropriate training. In order to execute the technical task on the shop floor in the assembly line, we hire top level engineering professionals. We do conduct internal training session to understand the technical updates required and cater to the industry demands. The same assessment has been reviewed by our top level management.        

At times, we experience challenges but overcome them by providing technical sessions that cover topics like modern manufacturing techniques apart from tool making or machinist, engineering and researcher skills, among others. In addition, we also conduct communication skill programs to work with team members and clients from all backgrounds and follow and deliver instructions. Activities for problem-solving and critical thinking to identify why certain processes are not functioning is also conducted. This includes the ability to ask questions and analyze weaknesses. Analytical skills to figure out how systems work and how certain aspects of working conditions, operations, and environment may affect the outcome of projects are also done by us. Additionally, we help our workers brush up on mechanical and technical skills to safely operate specialized machinery such as drill presses, milling machines, CNC machine operations, plasma cutting machine operations, poly epoxy chemical treatment plant, sand blasting, braze welding, shot blasting, milling, turning, handle metalworking or other complicated processes etc.           

Does the existing workforce get adequate exposure and opportunities to enhance and update their skills?  What are your initiatives in this area?

Based on the assignments, the workers are given tasks on a rotational basis. In this way, equal opportunities are provided to help them reach senior level. We conduct training, which is very important to enhance staff performance. Training and development ensure that staff possesses knowledge and skills needed to perform their jobs effectively and adapt to ever changing technology. We also make proper assessment of the taskforce and same has been reviewed by us. We reward employees taking extra responsibilities using skills and hard work. Proper exposure and equal opportunities are given to all of our employees. Apollo Techno focuses on skill development program to make their taskforce self-sufficient. The following are the initiatives to foster and cater to their skills       

• HR activities to enhance knowledge of employees
• Activities to improve job-related skills
• Activities to develop proper job-related attitudes
• Practices to prepare for higher responsibilities
• Initiatives to facilitate organizational changes
• Opportunities to enhance employee’s performance  

Digital transformation through disruptive technologies like artificial intelligence or robotics is being witnessed for enhanced productivity. What is the impact of this on your workforce?      

Robotics and manufacturing go hand in hand. Robotics plays a major role in the manufacturing landscape today. I believe automated manufacturing solutions should be a key part of any operation that strives for maximum efficiency, safety and competitive advantage in the market. Manufacturing robots automate repetitive tasks, reduce margins of error to negligible rates, and enable human workers to focus on more productive areas of the operation. We use CNC, robots, plasma cutting machines, laser engraving machines. Floor robotics machines are the key witnesses of enhancing productivity in lesser time. We can manage more work with less manpower; increase productivity with more systematic and scientific capabilities coupled with technological upgradation. With digital technology, low damage, perfection and few errors have been observed. Adopting these give our engineers breathing space and makes it easy for them to handle all production activities. Artificial intelligence and machine learning in particular is the new, powerful tool for minimizing consumption of additives and energy in almost every industrial process. Today, traditional manufacturing companies are actively beginning to implement machine-learning models to save costs. We are trying to modernize our factory, adopting upgraded tools and machineries.

What are the parameters put in place to ensure the workforce has requisite skill sets to perform the task in hand?

We follow scientific practices to access the requisite skills on floor like monitoring employee ability to handle material, understand supply chain systems and other operational activity, measurement skills etc. If they lack in certain areas, we perform the following sessions/skill development program:       

Traditional production skills: Tried-and-tested production skills like welding, machining, fabrication, etc.             

Computer-automated technol­ogies: The ability to operate and fix computerized and automated technologies that dominate the production environment today.  

Superior manufacturing practices: Quality-control processes that ensure the product meets quality requirements.

Industrial design: Creating products and systems optimized for manufacturability and efficiency.            

Sigma: Engineering and process improvement methodologies that improve efficiency and effectiveness by removing waste and reducing variation. Workforce is monitored by our senior team and well reviewed. We take corrective measures as and when required. 

According to you, what are the different initiatives that can be undertaken to foster the skill ecosystem within your sector?

As a manufacturer of HDD machines, we continue to move toward by creating advanced manufacturing workplaces, incorporating automation, robotics, artificial intelligence, and the industrial IoT. The ideas listed above may expand your ideas about necessary and impactful manufacturing training for the future. Following are the different initiatives that can be undertaken to foster the skill systems like critical thinking, problem solving, communication, teamwork and collaboration, learning agility, continuous learning program, willingness to change, innovation, digital skills development and  assessment, data analytics and adoption of Artificial Intelligence etc.            

Do you have any tie up with training associations like IESC for skill updation of the existing workforce?

Not yet, but in the future we are planning to tie up with some technical and management enterprises/associations.      

How do you assess the knowledge gap in the CE sector with regard to the standards of curriculum of different streams? What are the challenges?

We manufacture the horizontal directional drillings machine (HDD) at our Mehsana plant, serving the nation for OFC, power cable, water and sewerage pipeline and gas pipeline infrastructure development through HDD machines via retail and EPC/drilling contractors. HDD is itself a refined branch of the construction industry, followed by USA and Chinese standards.               

Apollo adopts USA standards adhering to quality parameters, which include low breakdown, high power, low operating cost, productivity, accessibility (quick spare parts and services), relevant to proper safety standards following the CE guidelines. China uses gear pump technology. This is a major challenge for us because we follow the axial piston pump technology, which is superior, efficient and expensive. We face competition with Chinese machine on the cost front and not due to the technology in use.

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