Excellence in Manufacturing Training: A Deep Dive into Kubota Manufacturing of America’s Award-Winning Program

In today’s competitive manufacturing landscape, winning the war on talent requires innovative training and development strategies. Kubota Manufacturing of America (KMA), this year’s winner of SME’s 2024 Excellence in Manufacturing Training Award, exemplifies how companies can effectively recruit, onboard, and retain skilled workers while fostering strong community ties.

Who is Kubota Manufacturing of America?

KMA is a cornerstone of Kubota Corporation's global operations. Based in Gainesville, Georgia, KMA is North America's primary manufacturing hub for Kubota products. Established in 1988, KMA has grown considerably and has become a significant regional employer, contributing to the local economy. The company produces diverse equipment, including lawn tractors, zero-turn mowers, sub-compact tractors, and utility vehicles. KMA exists to build a better future for its employees so that through them, it can make generational impacts on their families, their communities, and its customers. “We must create a sustainable, resilient, and growing business marked by continuous innovation in order to make our purpose possible,” said Tim Miller, Senior Training Manager at KMA.

During a recent webinar, we sat down with Miller, who shared insights into how KMA has built a successful training program.

The Importance of Strategic Workforce Development

The manufacturing industry is currently facing a critical shortage of skilled labor, a challenge that is further intensified by an aging workforce and the rapid pace of technological advancements in production processes. Companies like KMA are addressing this issue by developing strategic workforce development programs that not only meet its current needs but also anticipate future demands. These programs are crucial for maintaining a competitive edge and ensuring that its operations continue to run smoothly as they adapt to new technologies.

KMA's approach to tackling the skilled labor shortage involves proactive engagement with the local community, particularly through partnerships with educational institutions like Lanier Technical College and other local technical schools. These collaborations ensure a consistent pipeline of skilled workers who are trained specifically to meet KMA’s operational needs. The partnership goes beyond standard training, offering custom-designed courses that cover specialized skills such as specific welding techniques and safety protocols. Additionally, these educational partnerships serve as an effective recruitment tool, allowing KMA to attract students already familiar with the company’s culture and expectations, thus facilitating a smoother transition into the workforce.

Further demonstrating its commitment to fostering the next generation of manufacturing professionals, KMA has established partnerships with 14 local high schools, creating a work-based learning program that offers students hands-on experience in various aspects of manufacturing. This program is highly selective, targeting students who show a genuine interest in pursuing a career in the industry. KMA collaborates with school counselors to identify these candidates and provides them with mentorship and guidance from experienced team members. This not only helps students transition smoothly from the classroom to the shop floor but also inspires them to consider long-term careers in manufacturing. For KMA, this program is a vital component of its long-term strategy to build a skilled, committed workforce that will support the company's growth in the future.

Kubota's Comprehensive Training Programs

One of the core components of KMA’s training program is the assembly training module, which has been expanded from a day and a half to a comprehensive five-day course. This training is designed to equip new hires with the fundamental skills they need to succeed on the shop floor. The program starts with basic hand tool training, which might seem elementary but is crucial for those new to the manufacturing environment. This foundational training is followed by exercises on a mock moving assembly line, where trainees learn the importance of precision, timing, and coordination. By the end of the program, new hires will not only be skilled in assembly but also understand the importance of following standardized work processes to ensure quality and efficiency.

In addition to general assembly training, KMA offers specialized training programs tailored to the specific needs of its operations. The welding training, for example, focuses on MIG welding, a critical skill for producing the high-quality components that Kubota is known for. Trainees learn the technical aspects of welding and the importance of adhering to safety standards and making consistent, defect-free welds. KMA’s commitment to specialized training extends beyond welding; it also offers training in crane and hoist operations, ensuring that its workforce is versatile and capable of handling various tasks safely and efficiently.

Safety is a paramount concern in any manufacturing environment, and KMA has institutionalized this through its Safety Dojo. Regardless of tenure, every employee undergoes annual safety training in this unique training environment. The Safety Dojo covers three main areas: personal protection, situational awareness, and hazard recognition. Employees learn to use personal protective equipment (PPE) correctly, respond to uncommon but critical situations like chemical spills or fires, and identify and report potential hazards before they lead to accidents. This rigorous focus on safety protects employees and contributes to a culture of continuous improvement and vigilance.

The Role of Gemba Coaches in Employee Retention

Employee retention is a significant challenge in the manufacturing industry, particularly in the first few weeks of employment. KMA has addressed this by introducing Gemba Coaches—experienced employees who continuously support new hires during their critical first 30 days. These coaches engage with new employees daily, offering guidance, answering questions, and providing encouragement. This hands-on support helps new hires acclimate to the fast-paced manufacturing environment and reduces the likelihood of early attrition.

Beyond supporting new hires, Gemba Coaches are crucial in identifying and implementing process improvements on the shop floor. They observe workflows and look for opportunities to make tasks more ergonomic or efficient, such as adjusting the height of parts bins to reduce strain on workers. By continuously refining processes and addressing minor issues before they become big problems, Gemba Coaches contribute to a safer, more efficient work environment that benefits employees and the company.

Investing in the Future: The Learning Management System (LMS)

KMA’s commitment to continuous improvement is further demonstrated by its recent investment in a new Learning Management System (LMS). This system, being rolled out across the company, will revolutionize how training is delivered and tracked. The LMS will support web-based and instructor-led training, making it easier for employees to access the necessary resources to comply with safety regulations and develop new skills.

The new LMS will also enhance KMA’s leadership development programs. The LMS will help identify high-potential employees who are ready for more advanced roles by providing a centralized platform for tracking training progress and competencies. This system will enable KMA to offer more personalized training paths, ensuring that each employee’s development is aligned with the company’s strategic goals. Moreover, the LMS will facilitate better tracking of certifications and compliance training, essential in a heavily regulated industry like manufacturing.

Kubota Manufacturing of America’s award-winning training program is a testament to the power of strategic workforce development. By investing in comprehensive training, community partnerships, and continuous improvement, KMA has set a high standard for excellence in manufacturing. As companies across the industry seek to navigate the challenges of talent acquisition and retention, KMA’s approach offers valuable lessons in building a skilled and committed workforce.

For a more in-depth discussion of Kubota's award-winning training program, listen to the webinar: Building a High-Performing Workforce: Unveiling Kubota's Award-Winning Training Strategies.