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The 6th Annual Automation Education and Training Issue

Written by  Barrie White January 02, 2005
According to Skills Canada, Ontario needs more than 56,000 new high-tech workers this year, but there are only 14,000 technology students set to graduate in 2005. Some manufacturers see hiring and training apprentices as a solution to the skills shortage. (Pictured above: George Brown College students in the school&#39s microelectronics lab.) Not unlike many good ideas, Patheon's idea for an apprenticeship program came from a plant floor employee.

"Quite a way back, an employee came to me and asked to do it," says Bill Thrasher, who has managed maintenance and facility services at the company's 192,700-square-foot Whitby, Ont., plant for almost 20 years. "We said sure, and got the forms and did it, and that individual graduated as a journeyman and went on to be a group leader." A more formalized apprenticeship program began when the production department had difficulties hiring mechanics, says Thrasher, an M.M.P. graduate who heads the Durham chapter of the Plant Engineering and Maintenance Association of Canada (PEMAC).
"I said well maybe we [should] hire from our own," Thrasher continues. "They ran with it. They took two or three employees from the floor and put them into the apprenticeship program."

Thrasher had one foot on the apprenticeship bandwagon. He came fully on board after it became increasingly difficult to find skilled tradespeople. "We took 200 applications for electricians," he says. "We interviewed 10 and hired two. They were the best of the lot, and while they were close enough, they weren't exactly what we were looking for."

Patheon is a leading global provider of outsourced drug development and manufacturing services to pharmaceutical and biotechnology companies. It bought the Whitby plant in April 2000 from Novartis Pharmaceuticals when the apprenticeship program was still in its infancy. With all the changes, Thrasher became concerned the apprenticeship program would become an orphan. "I did a presentation to upper management outlining who we had enrolled and the reasons why we should continue with it," he says.

They liked what they heard.

Most companies-including his own in the beginning-find cost to be the biggest barrier to an apprenticeship program. But there are many reasons to hire apprentices, Thrasher says. "At the beginning it's an additional head count and there is not a lot of value. The biggest fear is we are going to spend a lot of time and money on this person and when they finish they are going to leave. Some 90 percent don't leave the company they apprentice for. However, let's face it: You have to have a competitive wage and benefit package or you'll lose them. We compete with the likes of General Motors and Ontario Power Generation."

The present and looming shortage of skilled tradespeople is another major argument for a company apprenticeship program, in Thrasher's opinion. According to an Ontario Chamber of Commerce survey, 41 percent of Ontario businesses expect to face a skills shortage by 2008 with the top reason being that Canadians still do not consider the skilled trades a desirable profession.

As far as Thrasher is concerned, the best tradesmen come from "a formalized apprenticeship program run with the Ministry of Training, Colleges and Universities."

To run a formal program, you need a set of rules, starting with the selection criteria including testing for entrants. So far, Patheon, which has 600 employees, has been plucking those with proven aptitude from the floor, and the program is seen as an incentive. But determining pay scales and schedules can be tricky.

Thrasher says, "We got together with some of the tradesmen in our plant ... and went over the training program [each apprentice] would go through ... to not only fulfill the requirements, but to turn out a good journeyman."

With help from the Ministry, Patheon devised a program for construction and maintenance electrician and industrial maintenance mechanic millwright consisting of 9,000 hours and 8,000, respectively. Nearby Durham College provides a classroom for the off-site learning portion.

Patheon had two employees in the apprenticeship program in December. This month, two more people from the floor entered the industrial maintenance mechanic millwright program.

If you are an expanding business like Pantheon, you must look at your future needs, Thrasher says. "You have to look at attrition. If you know someone is going to retire in three or four years, it makes sense to put someone in the apprenticeship program now. It is simply a part of succession planning."


Barrie White is a Toronto-based freelance writer specializing in industrial trade magazines.

How to attract (and keep) great apprentices

You're convinced that an apprenticeship program is a great way to help your plant meet its labour requirements when your older employees start looking over Florida retirement brochures. You realize that planning now will help your company continue to serve its customers' needs over the next five to 10 years. But what now?

The Canadian Apprenticeship Forum-Forum canadien sur l'apprentissage (CAF-FCA) is a federal government organization that promotes apprenticeship as an effective way to develop a skilled labour force. We asked Keith Lancastle, executive director, CAF-FCA, for tips on how to find and retain the best and the brightest apprenticeship candidates in automation and manufacturing. Here's what he said:

1 Knock out misconceptions about skilled trades. "We must begin by changing the way people, and in particular young people, perceive the skilled trades," Lancastle says. Skilled trades have not been considered a first-choice career option in young people's minds. As a result, we are not attracting the best and the brightest, but we should be. Talk to youth and show them that a career as a machine builder, plant manager or manufacturing technician has its rewards. "The challenge is getting people to shift attitudes on this, so that trades are seen as an acceptable career for the best and the brightest," he says.

2 Ensure your company is an employer of choice. A company's reputation will impact its ability to attract smart and talented young people. As skilled labour becomes scarcer over the next five to 10 years, competition for quality workers will become tougher, so it's important to make sure that yours is a company that a young person would find appealing. Also, it's important to make sure that advancement opportunities are available and visible to new hires to help retain the talent you've hired, Lancastle says. "As much as we tell employers that apprenticeships are a good long-term solution to their labour requirements, employees want to know that when they are investing their time in an apprenticeship, they, too, have long-term opportunities at the company from an advancement and training perspective."

3 Make contacts at the provincial ministry responsible for apprenticeship in your region. Before embarking on an apprenticeship program, employers should understand the prerequisites for being an apprentice in each province. The apprenticeship branch at your provincial/territorial ministry that deals with education, training and labour can provide this information. For a list of ministries and departments, visit www.apprenticetrades.ca.

4 Reach out to some of the high schools and community colleges to identify who the bright students are. Teachers are a great resource when you're searching for bright and talented young people who would make good employees, says Lancastle. Call your local school and ask the shop teacher who the best students in his or her class are. Programs such as the Ontario Youth Apprenticeship Program (OYAP) can also help you locate young talent. Call I-888-JOBGROW for more information about OYAP.

5 Network, network, network. Finally, ask your own internal network of employees, relatives and friends if they know someone who would make a great apprentice. -Nancy Kuyumcu

CAF-FCA is working on a tool kit for employers interested in getting involved in apprenticeship. Look out for the tool kit when it becomes available by visiting www.careersintrades.ca and www.apprenticetrades.ca.

Worker certification is keyto growth, says CEO

The greatest obstacle facing global manufacturing growth is a lack of skilled workers who can implement new technologies, according to manufacturing advocate Leo Reddy, chief executive officer and founder, National Coalition for Advanced Manufacturing (NACFAM).

In a keynote address at the recent Rockwell Automation Allen-Bradley Automation Fair ཀ, Reddy shared how his organization is implementing workforce certification programs based on industry-led standards. Reddy said that certification, similar to those in automotive repair and other industries, stimulates worker potential, and makes it easier for companies to deal with technology changes.

Reddy shared his findings of a NACFAM study based on interviews with more than 50 senior manufacturing executives. The study identified seven growing technology groups that will advance manufacturing over the next 15 years. The promise of these new technologies collides with the skill level of many of today's manufacturing workers, Reddy said. More than 80 percent of manufacturers report a lack of qualified workers, according to Reddy.

"The major barrier to the realization of these technologies is the shortage of engineers and technicians needed to research, design, develop and use them," Reddy said. "If we rely on the traditional education and training systems to fill this void, the payoff for consumers, businesses and governments will be delayed for many years." -N.K.

No lack of industrial talent in Alberta

While other provinces are scrambling to attract youth to the skilled trades to combat the looming skilled labour shortage, Alberta is brimming with industrial talent.

According to Gary Maier, engineering technology professor, Northern Alberta Institute of Technology (NAIT), Alberta's booming primary industries-particularly the oil and gas sector-are attracting many of the province's youth and lots of tradespeople from other parts of the country who want to cash in on the big paycheques available to ticketed workers.

"Plus, the whole idea of a tradesperson has changed over the years," Maier says, explaining that people no longer see a career in manufacturing as a "grease-under-the-fingernail" type of job. "The demands with automation and the requirements in terms of sciences and maths are significantly higher and employers are looking for people that have good thinking skills and are willing to learn," he says.

Another growing trend in the province, Maier says, is the idea of multi-skilled workers. As more companies adopt lean manufacturing principles, and as the workforce ages, multi-skilling-or training an employee to do a variety of related tasks so that he or she becomes a "jack of all trades"-is taking off. While multi-skilled workers benefit companies by making those workers more useful around a plant, it is often at the expense of plant maintenance personnel, he adds.

A version of this article first appeared in Plant Engineering and Maintenance (PEM) magazine. It has been edited and reprinted here with permission.

Last modified on April 26, 2005
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