Focusing on our future

Learn about a new apprenticeship program designed to educate our Fabrication Operations employees and also provide career direction.

By Anne Wiskerchen

For those dreaming of becoming a blacksmith during the Middle Ages, the path of learning began with an apprenticeship. After years of working under the watchful eye of a master craftsman, you might be granted the title of journeyman, and if your skills were eventually deemed worthy, you too would become a master craftsman.

In today's world, career paths are typically chosen and followed by formalized training at technical schools, colleges or universities. On occasion, workshop training also provides the necessary education and direction.

Senior Mechanic Lois Koftan concentrates as she drills parts on a multi-spindle drill press in Rockwell Collins Fabrication Operations in Cedar Rapids, Iowa.
Photo by Paul Marlow, The Creative Gene, LLC

Until recently, training for those who wanted to manufacture sheet metal products was limited. Much like the blacksmiths of yore, becoming an expert in this trade would take years of practice and on-the-job training.

But at Rockwell Collins, our Fabrication Operations business has solved that need for training and is in the midst of changing the way our company prepares and educates sheet metal and fabrication professionals.

In conjunction with Kirkwood Community College in Cedar Rapids, Iowa, the business is creating a formalized apprenticeship program for all Fabrication Operation employees.

"Many of our fabrication employees have 30 to 45 years of experience with our company," said Brad Marling, sheet metal manager for Fabrication Operations. "That's a lot of on-the-job knowledge that we will lose when they retire. To prevent that, we've created a program to educate our new and current employees."

As one of our company's main suppliers of sheet metal, aluminum and casting projects, it is imperative that our Fabrication Operations employees remain technologically competent, so it can continue providing our company with high quality components.

"We are focusing on the future," said Scott Shannahan, a fabrications facilitator in charge of hiring and ensuring employees complete the apprenticeship program. "We expect to see a lot of improvement in a lot of different areas as our program develops."

Getting out of your comfort zone

Starting a program of this size is not an easy task. To begin the planning process, a committee with an equal representation of day and night shift employees and management representatives was assembled.

The committee partnered with Kirkwood Community College to create a curriculum and determine the appropriate program length. A year-and-a-half later, the committee proposed that on-site classes be held twice a week for two hours during the work day. After gaining all necessary approvals, the committee moved forward with implementation and, in January 2007, the first group of students began attending the first set of classes.

According to Shannahan, this newly designed program will take three-and-a-half years for each class to complete. The current curriculum includes classes in mathematics, blue print reading, communications and computer skills.

Guy Stacy is a senior mechanic in Rockwell Collins Fabrication Operations in Cedar Rapids, Iowa. He is currently enrolled in our company's newly-created apprenticeship program.
Photo by Paul Marlow, The Creative Gene, LLC

"Although we work with these topics every day, it's good to go back to the basics and have some refresher training," said Guy Stacy, a senior sheet metal mechanic in Fabrication Operations.

With 10 years of service to our company, Stacy is actually considered one of the younger members of his team, but he still remembers being brand new and trying to learn all of our processes and familiarize himself with our equipment.

"I know what it's like to come in and not know what to do right away," said Stacy. "What we are learning now would have been very helpful early on."

All coursework is supplemented by on-the-job training so employees can gain experience on all equipment in the fabrications shop. This extra experience helps Fabrication Operations remain agile when workload increases or team members are out on leave.

"We have a lot of talent and very competent employees, but many were only comfortable on certain machines," said Shannahan. "We're not asking everyone to be an expert at every machine in our business, but this program will help them become familiar enough with our processes and tools to help out when special situations arise."

Currently, there are 60 students enrolled in the apprenticeship program from both the machine shop and sheet metal areas. Although the program is designed for new employees, it is currently being adapted to ensure all existing employees have the opportunity to take part. This adds the challenge of managing a change in expectations of our current workforce.

"In the past, people were hired and worked at the same job their entire career," said Shannahan. "Today, we need more than that; we need our employees to have skills in a variety of areas. It's best for our employees and for our business when everyone can get out of their comfort zones and gain experience on a variety of machines."

Investing in the future

The apprenticeship program at Rockwell Collins – the result of our company's commitment to and investment in our employees – is gaining attention in other parts of Eastern Iowa. In fact, local businesses are considering providing similar training for their workforces.

"Everyone agrees there is a major need to train people in these job skills and it takes a big investment by everyone involved," said Marling.

At Kirkwood Community College, the sheet metal training curriculum will be expanded, thanks to equipment donations made by many of our company's machine and equipment manufacturers.

"These are $150,000 pieces of equipment students can now practice on," said Marling. "This will allow them to apply the skills they learn in class."

In the future, Fabrication Operations intends to make this a nationally recognized program. The team also is planning on adding a curriculum on Lean Electronics and Fabrication financials.

Volume 12 Issue 3 > Deeply rooted in our heritage > Focusing on our future
Volume 12 Issue 3 Deeply rooted in our heritage Focusing on our future Delivering on our brand promise Feeding our economic engine One big, happy family Committed to customer support From Clay Jones Executive Profile - Kelly Ortberg Our heritage Letters to the editor Contributors in this issue Across our company Service anniversaries Retirees In memoriam Facility spotlight		Focusing on our future Learn about a new apprenticeship program designed to educate our Fabrication Operations employees and also provide career direction. By Anne Wiskerchen For those dreaming of becoming a blacksmith during the Middle Ages, the path of learning began with an apprenticeship. After years of working under the watchful eye of a master craftsman, you might be granted the title of journeyman, and if your skills were eventually deemed worthy, you too would become a master craftsman. In today's world, career paths are typically chosen and followed by formalized training at technical schools, colleges or universities. On occasion, workshop training also provides the necessary education and direction. Senior Mechanic Lois Koftan concentrates as she drills parts on a multi-spindle drill press in Rockwell Collins Fabrication Operations in Cedar Rapids, Iowa. Photo by Paul Marlow, The Creative Gene, LLC Until recently, training for those who wanted to manufacture sheet metal products was limited. Much like the blacksmiths of yore, becoming an expert in this trade would take years of practice and on-the-job training. But at Rockwell Collins, our Fabrication Operations business has solved that need for training and is in the midst of changing the way our company prepares and educates sheet metal and fabrication professionals. In conjunction with Kirkwood Community College in Cedar Rapids, Iowa, the business is creating a formalized apprenticeship program for all Fabrication Operation employees. "Many of our fabrication employees have 30 to 45 years of experience with our company," said Brad Marling, sheet metal manager for Fabrication Operations. "That's a lot of on-the-job knowledge that we will lose when they retire. To prevent that, we've created a program to educate our new and current employees." As one of our company's main suppliers of sheet metal, aluminum and casting projects, it is imperative that our Fabrication Operations employees remain technologically competent, so it can continue providing our company with high quality components. "We are focusing on the future," said Scott Shannahan, a fabrications facilitator in charge of hiring and ensuring employees complete the apprenticeship program. "We expect to see a lot of improvement in a lot of different areas as our program develops." Getting out of your comfort zone Starting a program of this size is not an easy task. To begin the planning process, a committee with an equal representation of day and night shift employees and management representatives was assembled. The committee partnered with Kirkwood Community College to create a curriculum and determine the appropriate program length. A year-and-a-half later, the committee proposed that on-site classes be held twice a week for two hours during the work day. After gaining all necessary approvals, the committee moved forward with implementation and, in January 2007, the first group of students began attending the first set of classes. According to Shannahan, this newly designed program will take three-and-a-half years for each class to complete. The current curriculum includes classes in mathematics, blue print reading, communications and computer skills. Guy Stacy is a senior mechanic in Rockwell Collins Fabrication Operations in Cedar Rapids, Iowa. He is currently enrolled in our company's newly-created apprenticeship program. Photo by Paul Marlow, The Creative Gene, LLC "Although we work with these topics every day, it's good to go back to the basics and have some refresher training," said Guy Stacy, a senior sheet metal mechanic in Fabrication Operations. With 10 years of service to our company, Stacy is actually considered one of the younger members of his team, but he still remembers being brand new and trying to learn all of our processes and familiarize himself with our equipment. "I know what it's like to come in and not know what to do right away," said Stacy. "What we are learning now would have been very helpful early on." All coursework is supplemented by on-the-job training so employees can gain experience on all equipment in the fabrications shop. This extra experience helps Fabrication Operations remain agile when workload increases or team members are out on leave. "We have a lot of talent and very competent employees, but many were only comfortable on certain machines," said Shannahan. "We're not asking everyone to be an expert at every machine in our business, but this program will help them become familiar enough with our processes and tools to help out when special situations arise." Currently, there are 60 students enrolled in the apprenticeship program from both the machine shop and sheet metal areas. Although the program is designed for new employees, it is currently being adapted to ensure all existing employees have the opportunity to take part. This adds the challenge of managing a change in expectations of our current workforce. "In the past, people were hired and worked at the same job their entire career," said Shannahan. "Today, we need more than that; we need our employees to have skills in a variety of areas. It's best for our employees and for our business when everyone can get out of their comfort zones and gain experience on a variety of machines." Investing in the future The apprenticeship program at Rockwell Collins – the result of our company's commitment to and investment in our employees – is gaining attention in other parts of Eastern Iowa. In fact, local businesses are considering providing similar training for their workforces. "Everyone agrees there is a major need to train people in these job skills and it takes a big investment by everyone involved," said Marling. At Kirkwood Community College, the sheet metal training curriculum will be expanded, thanks to equipment donations made by many of our company's machine and equipment manufacturers. "These are $150,000 pieces of equipment students can now practice on," said Marling. "This will allow them to apply the skills they learn in class." In the future, Fabrication Operations intends to make this a nationally recognized program. The team also is planning on adding a curriculum on Lean Electronics and Fabrication financials.