ExxonMobil, Beaumont, TX
Projects to create ExxonMobil GMT (Global Manufacturing Training) modules to match the processes in the Olefins (Furnaces and Ethylene Units), Synthetics (LoVis, HiVis and HVI), Aromatics (Hydrotreater, Cyclohexane, PreFractionation, Depentanizing, Water Treater, Utilities, Wharf) and Catalyst (Front End, Base, Cat 3 and Cat 4) Areas of the Beaumont, TX Chemical Complex have been completed. This completes the GMT Modules for the entire Chemical Complex - 872 modules consisting of over 1900 documents.
The projects to write Process Manuals for the Furnaces, Synthetics, Aromatics, Catalyst Areas and Aromatics have been completed: 101 Process Modules covering all the processes at the complex.
MTS World also completed a project to write Safety GMT Modules for the new hire Boot Camp training program.
Honeywell/UOP, Shreveport, LA
In April 2014, MTS World was awarded a project to analyze the current training system for operators at the catalyst plant and complete the first phase of document development and operator training. The first phase of the project was focused on a new reduction unit and included two new Process Operations Manuals and 15 Core Operations Manuals. MTS presented Learning How To Learn and led the training of eight new operators. The reduction unit started up in late 2014 and exceeded operational and quality expectations, much of which was attributed to well-trained operators.
Based on the success of the reduction unit training, the second phase of the project began in December 2014 to develop operating manuals for a new catalyst production line. This project included writing six process manuals, a line overview manual, a control manual and five utility manuals for the new line. Utility manuals covered Boiler, Cooling Water, Plant Air, DI Water, Nitrogen and Steam/Condensate operations. The project also nine additional Core Operations Manuals, Learning How To Learn and a Train The Trainer Course. Core and Process Training is currently in progress, led by Honeywell UOP, with a target completion of July 2015. The production line is scheduled for start-up in the fall of 2015.
LANXESS, Orange, TX
In January 2011, MTS World Gulf Coast began a project to revise 29 Process Manuals and write 15 new ones. We also trained 6 plant operators to write MTS style manuals to increase local input to the project. This project has been completed.
In February 2012, MTS World Gulf Coast began a similar project for the EPR Unit. This project involves writing 23 process manuals and training trainers.
Previous MTS projects were completed at this facility in the 1980s and 1990s.
Solutia Performance Films, Fieldale, VA
In March 2012, MTS World North America was awarded a project to analyze the current training system for operators at the films plant and implement a renewed system by the year’s end. The first phase of the project is focused on the largest production unit and includes seven new Equipment Operations Manuals and twelve new Process Operations Manuals. The project also includes Train the Writer, Train the Trainer, Learning How to Learn and DOC Training for the department. The project is underway and operator training is on track to be complete by December.
The second phase of the project is to assess the remaining production units in the plant and develop a training implementation plan for each department. This assessment project is scheduled for October 2012.
TETRA Technologies, El Dorado, AR
MTS World Gulf Coast completed a project to create a training system for operators and maintenance personnel at a new Calcium Chloride plant in southern Arkansas. The system included:
- Writing 21 site-specific operations training manuals
- Delivery of 73 weeks of operations and maintenance training using the site-specific manuals and manuals selected from the 1400 off-the-shelf manuals in the MTS Library.
- Training of plant personnel as MTS trainers to sustain the MTS Training System.
The initial project was completed in August 2009.
In 2012, MTS was brought back to update/revise the Packaging and Magnesium Area manuals.
Allnex (formerly Cytec Industries), Wallingford, CT
In November 2012, MTS World North America was awarded a project to analyze the current training system for operators at the resins plant and complete the first phase of document development and operator training by Ql 2013. The first phase of the project was focused on the key plant processes and included nine new Process Operations Manuals and 13 Core Operations Manuals. The project also included Train the Trainer, MTS led Operator Training, and Learning How to Learn for the department. The first phase of the project was completed on time meeting all deliverables and an aggressive project schedule.
The second phase of the project included nine additional Process Operations Manuals and Document Control Training for the project. Phase I I was completed in April 2013.
Allnex, Kalamazoo, MI
Based on the work at the Wallingford Plant, the Kalamazoo Plant contracted with MTS in March 2013 to
perform a training audit at their resins plant. As a result of the audit, MTS began Phase I in the summer of
2013 to write six Process Operations Manuals and conduct Train The Trainer and Document Control courses.
Allnex has been successfully training their operators using the MTS System over the past year.
Phase II of the project includes five additional Process Operations Manuals and scheduled to start in 2015
Allnex, Williow Island, WV
Likewise, based on the successful work at the Wallingford and Kalamazoo Plants, the Willow Island Plant
contracted with MTS in December 2013 to perform a training audit at their urethanes plant. As a result of
the audit, MTS began Phase I in early 2014 to write four Process Operations Manuals which were completed
Phase II of the project includes seven additional Process Operations Manuals and Train The Trainer and
Document Control courses. Phase II is scheduled to start in 2015.
Koppers, Inc., Cicero, IL
In September 2013, MTS World North America was awarded a project to update 20 Process Operations
manuals in the Phthalic and Tar Plants. The original MTS manuals were written in the 1980's and are still
used for training operators today. However, over the last 30 years, the MTS format has been improved,
with the current being a graphic format that is ideal for adult learning. The manuals are user friendly
delivered in PDF format and easily updated using native Word and Visio files.
The project began in late 2013 and is ongoing. The project also includes Document Control training,
allowing Koppers personnel the ability to review and revise the Process Manuals as needed.
Continental Aluminum, New Hudson, MI
In January 2011, MTS World North America was awarded a project to audit the maintenance system at the aluminum recovery plant. The result of the audit included training all maintenance personnel on Hydraulic Systems and Bearings and Lubrication. This project is has been completed.
In August, MTS continued with a project to assess the supervisors and lead operators. The audit resulted in a training plan that includes implementing the Leadership Development Process for all supervisors and lead operators. This project, along with additional assessment and training for maintenance, is expected to begin later this year.
PPG Industries, Strongsville, OH
Operations Training System implementation for a new powders paint facility. MTS wrote the manuals and trained the trainers. The manuals are now being updated using the MTS Documentation On Call (DOC) system.
PPG Industries, Circleville, OH
Operations Training System implementation for a continuous Acrylic Resin Plant. MTS wrote the manuals and trained the trainers. The training is being done by plant personnel. The manuals are now being updated using the MTS Documentation On Call (DOC) system. This is the third MTS project at this site involving new and/or existing operators. MTS has also assisted with installing a 4 year maintenance apprenticeship program which uses MTS training manuals, qualification skills and knowledge testing.
Citgo, Lemont, IL
Operations Training System implementation for a FCC Environmental Project involving the injection of NH3 into the CO Boiler flue gas, wet gas scrubbing and precipitation, and solids removal. Also this work involved documenting the Safety Interlock Systems for the FCC. MTS wrote the manuals and trained the trainers. The training is being done by plant personnel. The manuals are now being updated using the MTS Documentation On Call (DOC) system.
Citgo, Lemont, IL
Operations Training System implementation for a new Sulfur Tail Gas Unit including the Safety Interlock Systems. MTS is writing the manuals and will train the trainers. MTS has been working with CITGO at this location for 28 years doing projects involving existing units using CITGO trained personnel for writing and training and new projects involving MTS doing the writing and CITGO doing the training. CITGO is a recipient of the MTS 2007 World Class Award. See related article.
Metal Exchange Corporation, St. Louis, MO
Supervisor Assessment projects to determine training needs at the corporations aluminum facilities have been completed. Assessments were done at Metal Recovery Systems (St. Louis) and Electro Cycle (Madisonville, KY), ElementAL Holdings (Jackson, TN). Subsequent projects to provide training in the Leadership Development Process, consisting of 10 modules, began in 2010 and continue.