Training operators in the cold forming industry. Interview with Derek Barnes

It’s a cross-cutting issue for different sectors and different companies. The workforce is aging, and it is hard to convince recruits to join industries and subsequently train them optimally. 

Training for many companies, including those in the fastener industry, is often a sore subject. Many cold-forming businesses don’t have a real training program and simply rely on one-on-one coaching by “experienced” machine setters, which naturally makes everything more disorganized and error-prone.

It’s fair to say that operating a cold-forming machine, particularly multi-station transfer headers, is a complex task. Setting up such a machine so that it works well is not for everyone, and it takes skill to do it. To meet this challenge, attract young workforces - and convince them to stay! - it all needs to be approached methodically.

We interviewed Derek Barnes, an expert in cold forging technologies and in the development and training of operating personnel, to ask him what his approach is when it comes to training operators of a fastener-making business.

Where to start?
“Firstly, I try to understand the big picture. How does the organization work in the company? Apart from the machines and who’s running them, how do the supporting functions work? If all aspects are not in sync, the true potential of the production cell will not be realized."

What comes next?
“Developing a clear and documented training program, including machine training manuals, setting measurements, and specific drawings. Programs and manuals should contain all the information necessary for the setter to complete the job efficiently and are an indispensable work base, especially if you alternate between setters or operating shifts. All operators must set the machine in the same way! That is the only way to reduce changeover time, improve efficiency, and effectively troubleshoot machine problems.”



What role does a trainer play?
“The trainer plays a key role. He or she must be an experienced setter, besides having the patience and ability to understand people's individual learning needs. One does not improvise as a trainer. Learning to coach is a skill in itself, even though all trainers have their personal style they developed through their experience.”

What is essential in the training process, and when can it be said to be finished?
"It is crucial to record trainees' progress at all stages of the training process and provide feedback. Only once their competence has been assessed will they be considered ready for production. There must be a second phase of re-evaluation of their skills once they have gained some experience, which also serves to identify what additional information they need, to continue to deepen their expertise.”
But what do you start with, theory or practice?
“Definitely theory. Discussing and illustrating what happens during the process provides a solid foundation for the trainees, which can be referred back to when they begin to get their hands on the machines.”
What topics should the theoretical part cover? 
“The cold forming basics, understanding the machine mechanics, the wire properties, information about the tooling and what standard geometries can be formed - as a minimum. There are a lot of details to take into consideration and teach, but it’s also essential not to overwhelm the apprentices. The theory must be included in the documentation provided, or better yet, the trainee can take notes while the trainer presents the information.”

What about your method?
"I have developed a three-step training process based on the skills I have acquired during my multi-year career. It all starts with basic training, teaching how to assemble tooling, set the machine safely, understand the progressions, etc. Then you move on to gaining experience, supported by a mentor. The third part provides an in-depth understanding of forming theory and machine operation and imparts information on tooling and operating problems. We also analyze teamwork to improve efficiency. The continuous development of machine setters should be a top priority for any company that wants to improve performances and address customer satisfaction.”



About Derek Barnes:
After a successful career with a global fastener manufacturer, building and managing cold forging departments in the UK and North America, and educating operational personnel in a wide variety of businesses, Mr. Barnes became an independent cold forging engineering consultant. He is also the fastener specialist for the Confederation of British Metalforming.
For more information, you can write to [email protected]

Editorial note: Some content has been previously published in Fastener + Fixing Magazine.

Images of the machines courtesy of Carlo Salvi S.p.A.