At the end of 2015, Fiat launched its new car model, Egea (known as Tipo in the globe and autobest 2016). Tofaş has been the only producer for the world. Upon the high demand in the market, Tofaş had to increase the annual plant capacity from 240,000 to 375,000 cars and made a challenging plan to switch from 2 shifts to 3 shifts a day (24 hours continuous production).
This meant to hire and onboard 3,000 operators in the first 6 months of 2016. And the capacity increase should not have caused any deviation on both quality and safety.
Thus, we created and delivered onboarding programs for 3,000 operators (20 days) and 54 BPU leaders (31 days) with a 70-20-10 approach. The operation finished successfully in 6 months with 35 internal trainers and 28 technical mentors.
- 375,000 cars production capacity
- Zero Lost Time Accident,
- 8% First Time Quality