Since February 2001, the Welding School has been aggressively modernizing its training process, procedures, programs, and course content based upon the insertion of learning technologies, changes in welding procedures, and application of adult learning theory. It completed its modernization in December 2002 and has been operating under the new model since institutionalizing the modernized processes and procedures.

Modernization Initiatives and Accomplishments:

a. Developed a detailed Total Cost of Ownership Model both "Current State" and "Future State"
b. Updated and converted 90% of the Instructor Led Practical Training curriculum to Computer Assisted Instruction (Shielded Metal Arc Welding, Gas Metal Arc Welding, Gas Tungsten Arc Welding, Burning, and Stud Welding).
c. Developed 100% of the Instructor Led Classroom Training to Computer Based Training (Fire Watch, Fire Warden, Safety Evacuation Chair, Torch Safety, Visual Testing, Welding School Orientation, and Welding School Leader Training Course and Pre-Heat / Interpass).
d. Installed, implemented, and maintained a Learning Management System within the NGNN internal infrastructure.
e. Developed, validated, implemented a refined Assessment and Test Plan, data capture process, and analytical support program to ensure that the Return on Investment (ROI) prediction made in April 2001 was measured both empirically and anecdotally.
f. Developed the Modernized Welding School Training Model which features a Welding Basic Training to evaluate trainees early in the welding experience and then group them by learning styles and speeds to better match instructors to trainees providing a more efficient training model.
g. Developed a Welding School Staff Development Program focused on roles, responsibilities, and organizational changes to implement the modernized training model.

Results:

a. Decreased cost by 16% per initial entry trainee.
b. Maintained the quality level of the training the Welding School Graduates. Graduate X-ray test pass rate of 85% in 2000-01 compared to 83% in 2002.
c. Decreased the safety incident rate by nearly half. 2000-01 rate was 1.53% compared to 0.80% in 2002.
d. Increased available direct labor hours to the projects by 15,700 hours due to faster matriculation through the Welding School.
e. Increased initial entry trainee throughput by 3.6 times. 153 welders in 2001 compared to 555 welders in 2002 (plus 500 Lease Welders Qualification Tests).