Skill Gap Assessments & Closure Training

Report Deliverables:

FPA, LLC will provide a team with one or more Master Level Maintenance Supervisor and other qualified maintenance and reliability staff to perform a detailed maintenance assessment covering aspects such as organization, workflow, inventory, systems and software, key performance indicators, and training.  The deliverable will be a report with detailed findings and recommendations. A detailed assessment report will be provided upon completion of the assessment and will include the following:

  • Quantitative scorecard of the key areas
  • Observations of the current state of maintenance
  • Recommendations for improvement
  • Implementation Plan and schedule of client selected recommendations

Work Sampling Findings

Productivity as measured by Work Sampling is an indicator of the work process and not the caliber of the employees

Our Work Sampling Process provides the client an objective evaluation of its workforce productivity by identifying and quantifying barriers that impede effective work practices. Through statistical analysis of the collected data, organizations can focus efforts on mitigating or eliminating non-productive activities.

The three primary objectives of our Work Sampling Process are:

1. The quantitative assessment of the productivity or “wrench time” of an organization’s workforce.

2. The quantitative assessment of barriers which impede effective work. Work Sampling Findings

3. Recommendations for addressing identified work barriers. The work sampling process utilizes one of two methods: random sampling or worker shadowing and can evaluate productivity on a broad or detailed scale, depending on the objectives of the client.

Average ~30%
Best in Class ~60%

Various Measurement Techniques:

– Random Sampling
– “Shadow” Technique
– performed > 50 studies
– Majority have been via random sampling
– One study with shadow technique
– Average wrench time = 37%
– Range 20% – 49%

Skill Gap Assessments

Gap Closure Program





Maintenance & Operations Skills

Improvement Assessments

Craft Skills Gap Assessment

Operator Asset Care Training

Wrench Time Productivity

Maintenance Skills Training

Maintenance & Operations Skills
Improvement Assessments

Measurement Technique Types:

Random Sampling

“Shadow” Technique

Average wrench time = 37%

Range 20 – 49%

Performed > 65 studies

Skilled People have less injuries with planned work.

Human Capital Assessment & Improvement

Maintenance & Operations Skills

NCCER Compatible matrix for Skills Gap Assessment and Training

1= Never heard of job task before

2= Heard of job task before but never seen it completed before.

3, 4, 5, 6,7, 8 progressively increasing skill levels.

9= Has performed job task numerus times in a timely manner, using best practice and rework how gone to (0) ….

10= Is a master mechanic that can perform the job task in a timely manner, using best practices, knows all parts, tools, needed for the job task and can train best practice … Report details skill level of each staff member for Craft Skills

Report gives probability of success with training

Skills Gap Assessment

FPA delivers skills gap assessment. Results from recent wrench time study: client had an initial 27% wrench time utilization. 

National Average 

After 6 months of maintenance skills gap closure training and work control optimization, 2nd wrench time study found wrench time jumped to 49%. National Organization average wrench time 49%.

Final Results

After 12 months of skills gap closure training and work control optimization,  wrench time found continued  improvement as high as 70%.

Value of reducing lost time by 50% = $92,300 per maintenance tech per year. Or $1,384,500 for 15 staff

FPA Skills Gap Closure Training

Value of reducing lost time by 50%?

= $92,300 per maintenance tech per year.

$1,384,500 for 15 staff maintenance department.

How much capital must be spent and
product sold to generate $1.4MM in profit per plant?

Craft Gap Assessment

This is an onsite service conducted as an evaluation of one or more of your craftsmen. We assess the level of skill with plant maintenance tasks. It is conducted to see where your craftsmen skill set is at rated against national benchmarks and where improvement should be made. With training for the craftsman on recommended disciplines the reworks will decrease and the MTBF will increase. We offer on-site hands-on training that will shore up your craftsman’s skillset to achieve your maintenance goals.


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