The UK’s leading car plant called on AITT to bring its material handling training into line with the exacting quality standards synonymous with the Nissan brand.
At a glance:
| “As a plant, our success relies on staying efficient, and making sure our standards never drop. AITT have helped us ensure our material handling training meets that ethos.” Craig Smith |
Nissan’s Sunderland plant is one of the most efficient car factories in Europe – producing more vehicles per employee than any other site. It’s an ongoing success story that relies on the highest standards of training and organisation.
Since the plant opened in 1986, Nissan’s reputation for reliability has seen it become one of the UK’s leading marques. Eleven million vehicles have now rolled off the Sunderland production line, including not one but two of the nation’s most popular models – Qashqai and Juke and more recently the 100%v electric Nissan LEAF.
Challenge: Restoring high standards across complex training
At full capacity, the Sunderland plant can build 600,000 vehicles a year. This throughput – along with its Just-in-Time manufacturing philosophy – puts a strong emphasis on its material handling team to keep production running. Combined with the site’s Job Rotation policy, it created a complex, high-stakes challenge for Training Controller Craig Smith.
“We’re a large material handling site,” Craig explains. “We’ve got over 350 vehicles: forklifts, reach trucks, tow tractors, MEWPs and more. Plus our EOT crane, lifting up to 40 tonnes. We’ve more than 40 instructors, most of whom also work on the production line. Managing all the standards was a big ask.
“Unfortunately, our previous accrediting body seemed to forget the ‘Advisor’ part of ‘Training Standards Advisor’. We needed more practical guidance, to ensure our tutors didn’t become lackadaisical, and really did pass on the information needed to help instructors meet the relevant national standards.”
Solution: Tailored, constructive advice from AITT
After comparing alternative accreditation partners, Nissan were drawn to AITT’s high levels of advice and support – working closely to help its instructors maintain the highest training standards.
Craig recalls: “With some providers, instructors get a pass or fail in an envelope, and they’re out the door – no understanding of what they did well and where they could improve. But when Dave, our TSA from AITT, comes to assess us, it’s different. It’s more about sharing best practices and understanding how to correct things and get back to the standard where we should be.
“The handover process was really easy, too. AITT’s technical team, Jules and Peter, spent the day with us, showing our tutors the small differences with the documentation and processes. Then the next day it was our accreditation visit.
“They spotted some issues our previous partner hadn’t and gave us advice on how to fix them. Easy peasy – done.”
“Both as a tutor and a manager, AITT’s team help me to maintain those high standards, and make sure I keep passing the right knowledge down to my instructors. They give me homework, and they’re realistic about the timelines for delivering change, which I really appreciate.”
Craig Smith
Training Controller, Global Training Centre, Nissan Motor Manufacturing UK
Result: Consistent, high-quality training across all equipment types
Following support and advice and enhanced documentation from AITT, Craig is far more confident that every aspect of Nissan’s material handling processes, instructors, and operators meet the relevant national standards. The improvements are also helping Craig’s team to support equivalent training overseas, and to raise standards at Nissan’s tier-1 suppliers in turn.
Before: Training standards could be inconsistent and risked being out of date.
After: Complete confidence that instructors and operators are always trained to the right standards.
Craig concludes: “Our relationship with AITT shows we’re dedicated to the highest national standards. We’re assessed regularly, and where there’s an issue we’re supported to put things right. For instance, our crane training had fallen behind the latest standards; AITT spotted that, and we corrected it. AITT’s publications are also much more user friendly, so our instructors are happier too.
“Overall, I’m very impressed. I’ve already recommended AITT to some of my peers – I just show them the quality of the instructors books, and they can immediately see the difference.”
“With AITT, the technical team is always there to help and support us – we’ve called a couple of times, and advice has always been spot on. It gives us confidence we’re always delivering the best instruction we can.”
Craig Smith
Training Controller, Global Training Centre, Nissan Motor Manufacturing UK
