Virtual training first definition presentation

1. Virtual training first definition presentation

2. Objective The following presentation has the objective of defining the proposed virtual training system from a functional perspective as well as give some insight into some of the technical aspects

3. Contents • Proposed approaches to using the system • Proposed modules • Proposed categorization of information necessary for the training process • Some advantages of a using database

4. Proposed set of approaches • Search approach Set of modules designed for fast retrieval of pre-existing information • Mailbox approach Set of modules for asking questions to the experts • Administrator approach .- Set of modules for adding and deleting pre-existing information • Monitor approach .- Set of modules used for monitoring the performance of the elements of the process

5. Search approach The user logs into the system and looks for existing information

6. Proposed Modules • DVD Tests Module. • DVD parameters definition Module . • DVD parameter troubleshooting Module. • Machine operation (80/20) Module. • Machine theory, specifics and troubleshooting Module(Digitized users manual) . • Process information by employee position Module . • Safety issues Module .

7. DVD Tests • Descriptions of each test • Importance of each test in the QC process (Including explanation of the reason for measuring same parameters in different tests) • Parameters measured in each test (Each with a link to their respective Parameter Definitions) • Physical testing devices for each test (Name of device, description of device, physical location of device in the floor) • Methods for testing different DVD formats and clear substrates • Special considerations • Example • 3 point – Asym,RRO,… • Multipoint – Jitter, R14,… • Prometeus – Absolute birefringeance, layer thickness,… • Dr. Schenk - S,F,H2,N,ST,…,V

8. DVD parameters definitionParameter dictionary (Including Dr. Schenk errors) • Listing of all DVD parameters with their : • Respective physical descriptions • Text description • Graphical description (Diagrams, pictures or videos) • To which DVD format each parameter applies • Minimum and maximum values (when it applies) • For the appropriate parameters say if it is an error by itself (For example injection flaw or bonding gap that have no numeric values) • Respective links to the DVD Teststhat measure each parameter • Respective links to the DVD parameter troubleshooting • Special considerations

9. DVD parameter troubleshooting • Listing of all DVD parameters with a link to DVD parameters definition • Description of the possible causes by order of occurrence • Description of the solutions for each possible cause • Text descriptions of the solutions • Fixed field descriptions of the solutions when applies • Graphical descriptions of the solutions(Diagrams, sequences, pictures, video and voice) • Related secondary effects of changing parameters – Eg. If temp increase jitter is fixed but radial or tangential can occur • Example • Injection flaw -> Sumitomo -> Decrease 1st & 2nd injection speeds • R14H0 -> Check substrate thickness – OK -> Increase sputtering Units in SP2 • - NOK- >Sumi ->Increase 4th position • - >Meiki ->Increase SO

10. Machine operation (80/20) • FOR EACH TYPE OF MACHINE molding and downstream(Based on the most common types of alarms, human errors and machine malfunctions) • Description of the procedures (Do’s and Don’t’s) for starting, running and stopping a machine for optimal results in the case everything works well (Eg. Do not bypass the 15 minute wait after heat up is complete in the Sumitomo, Purge air in the Meiki molding machines after stopped for a while to avoid mold breaking) • Listing of the most frequent problems when starting up a machine(There is no Polycarbonate in the container) • Listing of the solutions to the most frequent problems when starting up a machine(If there is no polycarbonate in the container, check if the switch is turned on, if ON go to left hand corner of the floor and look in the monitoring display that your machine is activated in the Polycarbonate piping system ) • Listing of the most frequent problems when running a machine (alarms due to wasted substrates, broken sprues, robot not grabbing substrate, link to the digital users manual-when existent ) • Listing of the solutions to the most frequent problems when running a machine • Listing of the most frequent problems when stopping a machine • Listing of the solutions to the most frequent problems when stopping a machine

11. Machine theory, specifics and troubleshooting(Users manual) • This module will contain a detailed users manual for the molding and downstream machines. The arrangement will be similar to the arrangement in the text users manual, however, the user will have the advantage that the information will be extracted faster by using key words and indexes in alphabetic order, the links will also provide faster mobility within the manual’s content • The content will include detailed theory of the industrial processes involved such as: • Mastering • Sputtering • Bonding • Curing • The module will also include information about not so frequent problems such as what to do when Dr. Shenk goes offline or when the UV process is failing because of lack of vacum or low operating temperatures. The information will be arranged by groups of processes and then by alphabetical order. Whenever new complex problems occur , the fixer of the problem will have the option to include the new problem in this module by logging to the system as an administrator and adding the new problem • There will be information that relates different processes by means of machine paramenters

12. Process information by employee position module • This module will provide with the specific job functions for each individual so that he is always at least, doing his job correctly • List the responsibilities for material handlers (Categorize remaining materials, take the metallized material to the silo and the rest to the recycling) • For each, provide a detailed explanation • List the responsibilities for operators • For each, provide a detailed explanation • List the responsibilities for technicians • For each, provide a detailed explanation • List the responsibilities for engineers • For each, provide a detailed explanation

13. Safety issues module • This module will provide with the most important safety rules and aspects of working in the floor (Some of this material may be found in the MSDS, however, the material is cumbersome and it takes a while to find any kind of information) • Hazards code • Hazards of the chemicals used • Lacquer • Acetone • MIBK • Alcohol • Over burned polycarbonate • Hazards in the air • Description of the particular smell in the air of the floor • Description of how to handle the contaminated shoes at home – When lacquer gets home through the shoe soles, it is as dangerous as it is in the floor, possible accidents could also occur at home and nobody will know if the accident happened in the production floor or at home. This could be specially valuable for new employees and for those who have kids • Description of how to handle the contaminated clothes at home • Rules of safety • Recommendations of safety

14. End of Search approach

15. Mailbox approach The user logs into the system when he wants to provide feedback

16. Proposed Modules • Questions module . • Recommendations module . • Answers module . • Frequently asked questions module .

17. Questions module • This module will be for asking a question of any kind, the question can be directed to somebody in particular when the user knows who can answer, or it can be sent to a group of people. The actual question will not be mailed to the recipients, only a notification that there is a question that needs to be answered and a link to log directly into the virtual training system, later the employee will be able to read the answer in the Answers module, the answer is also sent to a group of experts that certify the answer for later inclusion into the database as part of the knowledge base. All the information regarding the process will be recorded in the database to have a control of the following: • Employee who asks, date and time of question, if he directed the question to somebody, to whom, date and time the question was answered, author of the answer, if the answer is certified by the group of experts • The fields in the screens will be the following • Employee ID - Who asks • Question space – What is asked • Recipients – To whom is the question directed • An expert individual – To the individuals assigned for question answering (These people have to be experts in the area) when the user knows exactly who can answer the best his specific question • Group of experts – When the user is not sure who can answer his specific question. This group of experts have to be registered in the system as official answering individuals • Confirmation of submission - If the question arrived to the recipients

18. Recommendations module • This module will have the objective of sending a recommendation to a selected individual or a group of individuals, the recommendations made will be stored in the database together with the date and time they where made: • The fields in the screens will be the following • Employee ID - Who makes the recommendation (optional) • Recommendation space – What is the recommendation • Recipients – To whom is the question directed • An expert individual – To the individuals assigned for receiving recommendations. Used when the user knows exactly who to address his recommendation to • Group of experts – When the user is not sure who to send his recommendation to • Confirmation of submission - If the question arrived to the recipients

19. Answers module • This module will be accessed by the user whenever he decides to, however, the time and date he logs in and checks for his answer will be recorded to monitor end of answering process as well as the employees that show more interest and which could eventually be trainers themselves: • The fields in the screen will be the following • Answer field – Where the user can read the answer to his question or the confirmation of his recommendation or a comment from the recipient • Type of answer • Answer to a question by employee XXXXX • Response to a recommendation by employee XXXXX • Comment from the recipient of question by employee XXXXX • Confirmation of recommendation received • Download, play or link button – In the case the answer is already in the database • Author of answer – So that the user knows who to ask or not to ask next time he has a similar question • Grading of answer link– The user will assign a grade to his level of satisfaction after he reads the answer • Certified answer– A Boolean field that notifies the user if this answer has already gone through the certification process and that it is already cleared. The answer is ready to be included in the database and to be used effectively by the user on his job in the floor • Status of answer – Answered/not answered, Certified/not certified, in process of certification.

20. FAQ module This module will be part of the most frequently asked questions and will be grouped in different categories, the answers to these type of questions will have to be previously certified by the group of experts

21. End of Mailbox approach

22. Administrator approach The user logs into the system when he wants to update the database

23. Proposed Modules The administrator will be able to manipulate all the information and access privileges for each module of each approach, the administrator will be the responsible of standarizing the raw information that comes from the text input from the user. The administrator modules will be defined after all the modules are defined in detail. • FAQ’s updating module • New information insertion and deletion

24. End of Administrator approach

25. Monitor approach The user logs into the system when he wants to monitor the _training process (Insight to the statistics of the system/process)

26. Proposed Modules • Graphs • Most searched material • FAQ’s • Employees’ number of questions • Employees’ number of searches • Time it takes for a group to answer • Time it takes for an individual to answer • Time it takes for the trained employees to retrieve their answers • Time it takes for the process of certification to complete • Most asked individuals • Most asking individuals • Level of satisfaction of the answers received • Comments and complains about the system • Comments and complains about a process issue • Checklist of learning – E.g. If an operator has to be trained in process 1,2 and 3 and he logs into the system to search for material 1,2 and 3 and is comfortable with the information received, then the check boxes 1, 2 and 3 would appear checked • Link and extraction of data from Infodisc’s productivity databases – To check every certain period of time how the system is impacting the yields , cycles and wasted material • Current and shift status of machine

27. End of Monitor approach

28. Some Advantages of using a database • Data integrity.- By making the information reside in a database, integrity is preserved, if one piece of information needs to be changed it is safer to change it only once and be automatically updated every where than manually change it in every required section. Human error probability is reduced • No data repetition .- Given the fact that many themes in the DVD production are interlaced, if information is not simplified, a lot of information could be repeated. If one theme or piece of information is to be changed or updated in a printed manual, then the same update or elimination would have to be done for every single theme that is affected by the change. Depending on the size of the content, the latter way of working could create administration and chaos problems in the future. Example: If we wanted to add the explanation of injection flaw we would have to update the same explanation to the Meiki, Sumitomo and to the e mould machine sections whereas if we have an automated database system, we would only have to update the information once for the three different types of molding machines. • Speed of extraction .- The speed of data extraction is much faster when one person only has to type a couple of words or click several related links than if he has to turn pages backwards and forwards. In the production environment, the employee lacks of time for “on the job training” and the small periods of available time should be optimized. • Easy administration and controlled growth capabilities.- Control allows manageability, and enhances the potential for controlled growth thus diminishing future re working. • No printouts.- Less hard copies, less cost. If one page or section is to be updated, it would only be necessary to make the change once without the need to make hard copies. One update good for all. • Multimedia capability .- Capability of video, animations and voice explanations. • Possibility of networking the machines .- By adding Internet Explorer to the Singulus Machines, the database could be accessible immediately in all the machines. • Portability of information .- If the employee needs to give further study to a printed manual, it is easier and faster to click the print button to print the current page than taking the whole manual to the photocopier. • Monitoring capabilities .- By checking how many times are the employees logging into the training system, the cost benefit ration could be better assessed as well as the behaviors of the formers thus allowing the HR department to make changes fast and effectively if something is not working as expected. • Dynamic on demand growth .- By allowing the employee to give feedback and to ask questions the growth of the system could be streamlined through adding value channels.