1.5 Competence & Training Management (Skills Matrix)

In electronics manufacturing, "Training" is an event; "Competence" is a demonstrable outcome. An operator who "attended the class" but cannot distinguish a cold solder joint is a liability, not an asset. Unqualified personnel are the single largest source of variation in manual assembly processes. As a Quality Director, you must shift the metric from "Training Hours Completed" to "Process Capability Verified." If an operator touches the hardware, their competence must be certified, tracked, and capable of revocation.

The Skills Matrix Architecture (ILUO)

The Skills Matrix is not an HR spreadsheet; it is a tactical deployment tool for Production Management. It visualizes the risk level of the shop floor in real-time. Use the ILUO grading scale to quantify flexibility and depth:

• I – Intro (Trainee): Can only work under direct supervision. No authority to sign off work.
• L – Learner (Independent): Can work alone on standard tasks. Meets cycle time and quality targets.
• U – User (Expert): Can train others and troubleshoot minor issues. High consistency.
• O – Owner (Master): Can improve the process, rewrite Work Instructions (WI), and lead Kaizen events.

Decision Logic for Line Balancing:

• IF a station has only one "U" or "O" level operator:
  • THEN That station is a "Single Point of Failure." Cross-train immediately.
• IF New Product Introduction (NPI) build:
  • THEN Only "U" or "O" level operators are permitted. "I" and "L" levels are restricted to mature, stable product lines.

Certification vs. Attendance

Do not confuse "knowing" with "doing." Certification requires objective evidence of skill.

The Certification Protocol:

1. Theory: Review the Work Instruction (WI) and Standard Operating Procedure (SOP).
2. Observation: Trainer demonstrates; Trainee watches.
3. Supervised Practice: Trainee performs the task; Trainer corrects.
4. Qualification Run: Trainee performs the task (e.g., builds 10 units) without intervention.
   • Criteria: 100% Quality yield + Cycle Time adherence.
5. Sign-off: Both Trainee and Trainer sign the matrix.

Pro-Tip: Recertification is not automatic. If an operator has not performed a specific task (e.g., Hand Soldering) in > 6 months, their certification expires. They must revert to "I" status until re-verified.

The "Decertification" Trigger

Competence is not a lifetime appointment. The Quality System must have a mechanism to revoke privilege when performance degrades.

Revocation Logic:

• IF Operator produces a critical escape (Customer RMA):
  • THEN Immediate decertification on that process. Retraining required.
• IF Operator is found violating a "Cardinal Rule" (e.g., disabling safety guards, falsifying data):
  • THEN Disciplinary action + Permanent removal from that station.

Final Checklist

Control Element	Parameter	Critical Rule
Matrix Visibility	Accessibility	Displayed on Line (or digital equivalent)
NPI Staffing	Skill Level	Min Level "U" Required
New Hires	Supervision	100% Audit until Level "L" achieved
Expiration	Dormancy	Revoke if inactive > 6 months
Trainer Authority	Qualification	Only Level "O" can sign off new staff
Records	Audit Trail	Retain indefinitely (ISO 13485 Req)