Summary description:
Program ObjectiveThis 12-week program trains transitioning service members to safely and independently operate Continuous Compression Molding (CCM) equipment used in composite laminate production while meeting aerospace-quality manufacturing standards.The trainee will progress from safety fundamentals to full independent machine operation with documented competency validation.
Job description:
Week 1 – Safety & Compliance OrientationFocus: Workplace safety and manufacturing fundamentalsTraining Topics:• Facility orientation• PPE requirements• Heat and pressure hazard awareness• Lockout/Tagout (LOTO)• Chemical handling procedures• Environmental and company compliance policies• Introduction to AS9100 quality awarenessPerformance Objectives:• Demonstrate proper PPE usage• Perform LOTO procedure under supervision• Pass safety knowledge assessment (minimum 85%)Supervision Level: Direct supervisionEvaluation Method: Written quiz + practical demonstration________________________________________Week 2 – CCM Process FundamentalsFocus: Understanding materials and documentationTraining Topics:• Continuous Compression Molding process overview• Composite materials (resin systems, fibers, laminates)• Reading setup cards and work instructions• Basic blueprint/drawing interpretation• Introduction to HMI interfacePerformance Objectives:• Correctly interpret setup card• Identify key machine components• Navigate HMI screensSupervision Level: Direct supervisionEvaluation Method: Supervisor observation checklist________________________________________Week 3 – Machine Setup (Assisted)Focus: Assisted machine preparationTraining Topics:• Heating die preparation• Building stackups• Loading creels• Startup and shutdown proceduresPerformance Objectives:• Assist with 3 machine setups• Identify correct temperature and pressure parameters• Follow startup checklist without omissionSupervision Level: Direct supervisionEvaluation Method: Setup checklist sign-off________________________________________Week 4 – Machine Operation (Assisted)Focus: Parameter control and monitoringTraining Topics:• Adjusting temperature, pressure, and speed• Alignment verification• Monitoring HMI for consistency• Material feeding techniquesPerformance Objectives:• Perform parameter adjustments under supervision• Maintain stable production run for minimum 2 hours• Document production data correctlySupervision Level: Close supervisionEvaluation Method: Production run review________________________________________Week 5 – Introduction to Quality ControlFocus: In-process inspectionTraining Topics:• Thickness measurement• Dimensional verification• Surface finish inspection• Visual defect identificationPerformance Objectives:• Inspect 5 production samples• Correctly identify common laminate defects• Complete inspection report accuratelySupervision Level: Close supervisionEvaluation Method: Quality Manager review________________________________________Week 6 – Documentation & TraceabilityFocus: Production and quality documentationTraining Topics:• Batch records• Traceability requirements• Nonconformance reporting process• Shift turnover communicationPerformance Objectives:• Complete full batch record independently• Accurately document inspection data• Conduct simulated shift turnover briefingSupervision Level: Moderate supervisionEvaluation Method: Documentation audit________________________________________Week 7 – Independent Setup (Supervised)Focus: Increased responsibilityTraining Topics:• Full machine setup• Parameter verification• Pre-production checklist validationPerformance Objectives:• Complete 1 full setup with minimal assistance• Verify all machine parameters correctly• Meet setup time standard within 15%Supervision Level: Observation with intervention as neededEvaluation Method: Supervisor competency checklist________________________________________Week 8 – Production Monitoring & Process StabilityFocus: Maintaining consistent qualityTraining Topics:• Process drift recognition• Thickness variation causes• Surface defect root causes• HMI trend monitoringPerformance Objectives:• Maintain stable run for full shift• Identify 2 simulated process deviations• Escalate issues appropriatelySupervision Level: ObservationEvaluation Method: Production metrics review________________________________________Week 9 – Troubleshooting FundamentalsFocus: Process issue identificationTraining Topics:• Common CCM failures• Alignment issues• Temperature drift• Material feed problemsPerformance Objectives:• Diagnose 2 process issues• Recommend corrective action• Document issue reportSupervision Level: Guided troubleshootingEvaluation Method: Supervisor review________________________________________Week 10 – Preventative MaintenanceFocus: Equipment care and contamination preventionTraining Topics:• Preventative maintenance schedule• Die cleaning procedures• Component inspection• Reporting mechanical concernsPerformance Objectives:• Participate in 2 PM cycles• Perform supervised die cleaning• Complete maintenance checklist accuratelySupervision Level: Moderate supervisionEvaluation Method: Maintenance log verification________________________________________Week 11 – Independent Operation (Observed)Focus: Full operational responsibilityResponsibilities:• Machine setup• Parameter control• In-process inspection• Documentation completion• Shift reportingPerformance Objectives:• Meet production rate within 10% of standard• Zero safety violations• Complete full documentation packageSupervision Level: Observation onlyEvaluation Method: Performance evaluation_______________________________________Week 12 – Final Qualification & AssessmentFocus: Demonstrated competencyEvaluation Includes:• Full independent machine setup• 4-hour monitored production run• Quality inspection verification• Documentation audit• Troubleshooting scenarioQualification Standard:• No critical errors• 100% documentation accuracy• Meets safety and quality expectationsOutcome:Upon successful completion, trainee is qualified for independent CCM Machine Operator duties.
MOUs on file
Eligibility factors:
All Services
• Ability to lift 50 lbs• Ability to stand for extended periods• Must meet vision requirements for quality inspection• Must be eligible to work in CUI/CMMC‑aligned environments post‑service• Must complete TRP requirements per DoD policy
