Course Information

FETAC Level 5 Lean Manufacturing Tools Program

TARGET AUDIENCE

This course is aimed at personnel who are responsible for developing and improving processes in a cost effective manner. This includes, but is not limited to:

• Engineers & Technicians: Process, Manufacturing, Validation, Quality, Laboratory, HSE  
• Leaders/Managers overseeing people who complete lean improvement activities

 PRE REQUISITES     This course assumes no/little prior experience of lean.

PROGRAM OBJECTIVES

A Lean Enterprise delivers maximum value to its customers using the minimum amount of materials, labour, finance and other resources. Learners who successfully complete this module will be able to:

1.    Conduct Lean improvement activities in their own area of responsibility, such as 5S, Kanban, SMED, Standard Work and Mistake Proofing

2.    Assist senior management in implementing Lean Principles in a wider manufacturing environment

PROGRAM SYLLABUS

 Note: Plant visits and exercises will be coordinated by R. McEvoy through SELF (South East Lean Forum)and/or the participants own plants. The VSM & SMED exercises will be conducted at a participant’s plant.

ASSESSMENT

For FETAC certification, each candidate will complete the following:

1.       A written assessment

2.       A skills demonstration and presentation

3.       A project and presentation

1. Written Assessment

The internal assessor will devise a brief that requires the candidate to produce evidence that demonstrates an understanding and application of a range of specific learning outcomes. This assignment will require the candidate to demonstrate an understanding of the Lean Thinking and Lean Fundamentals learning outcomes. It will be in the form of a written assessment (1,000-2,500 words) of the candidate’s own organisation, making a preliminary assessment of the extent to which Lean Tools have already been implemented and also identifying the potential for further improvement. It should clearly identify the extent (including examples) of the seven wastes.

2. Skills Demonstration

The candidate’s skill in both compiling a Current State Value Stream Map (VSM) and proposing a Future State VSM will be assessed. The candidate will create both a Current State Value Stream Map and a Future State Value Stream Map for a significant product/service within their organisation. As well as submitting a hardcopy of both maps (A3 size), the candidate will make a short (10 min max) presentation to the class, outlining the issues identified and solutions proposed. This assessment will test all of the Learning outcomes in Unit 8, as well as at least a selection from Units 2, 4, 5 and 6. This VSM may, but not necessarily, form the basis of the candidate’s subsequent project. This presentation will be video recorded, with each candidate clearly identified, for the purpose of external moderation.

3. Project

The internal assessor will agree a project brief with each candidate that requires candidates to demonstrate both an understanding of aspects of at least some of the Lean tools and the ability to implement those tools within their own workplace. It is acceptable for several candidates to cooperate on a team project as long as each candidate satisfies the internal assessor that they both understand the tools used and played a significant role in the implementation. The project must be completed and presented within 3 months of completion of the course. The presentation format shall be suitable for presentation also to the candidate’s own management and may include flipcharts, PowerPoint presentation and results achieved to date. The presentation is expected to last 20 mins for a single-handed project. The project may, but not necessarily, be based upon the VSMs created in the Skills Demonstration. The project should demonstrate the candidate’s achievement of a broad range of the learning outcomes. This presentation will be video recorded, with each candidate clearly identified, for the purpose of external moderation.

PROPOSED TIME COMMITMENT

ABOUT THE TRAINER

The trainer for this course is Raymond McEvoy of Manufacturing Excellence, Raymond McEvoy is a certified Lean Enterprise Expert, 6 Sigma Greenbelt and Total Quality Facilitator and has facilitated or participated in Improvement Events in USA, Germany, France and UK.

He has accumulated over 20 years manufacturing experience in the aerospace and automotive industries, with both Irish-owned and multi-national organisations. This has ranged from the low-volume, wide-scope design and manufacture of specialized transport systems to the high-volume manufacture of critical aerospace components.

He has been a key player in successfully guiding an organization from greenfield startup to critical integration with the parent company. He has been responsible for designing and implementing Quality systems for ISO 9002, MIL-I-45208 & CQC-103, as audited by AlliedSignal, Honeywell, Rolls-Royce and Boeing.

INCLUDED IN COST

1. FETAC certification process
2. Venue, Refreshments and Lunch
3. Hard copy of comprehensive notes  
4. Co-ordinated site visits

CONTACT DETAILS

Contact Name: Maria Ryan, Training Course Manager
Mobile:               +353 87 6226899
e-mail:                maria.ryan@crystalbusinesssolutions.ie

Website:             www.crystalbusinesssolutions.ie

Registration:        Training Registration Form

Training Calendar: Training Calendar

PROGRAM DURATION       5 days

PROGRAM COST                 €TBC.00 per person

Appendix: Description of Course Layout

The initial Lean overview module explains the history of manufacturing from craft, through mass production to Lean, and also offers case studies of successful transformations. The key concepts of Value as seen by the customer, Value-Adding and non-value-adding steps are introduced and explored.

The Spot Dot game simulates some of the problems in a typical mass-production or batch & queue process and encourages participants to find the Lean improvements using some of the concepts already introduced.

Participants are also requested to select or develop 3 metrics in their own plant that will be the principal measure of effectiveness of their project. It is critical that this is done at an early stage, so that learning is focused on their own project.

Informal feedback is sought each day on the clarity and effectiveness of the training.

Tools of continuous improvement are introduced and the setting of SMART objectives as they will be needed to challenge the status quo. 5S workplace Organisation, including a convincing simulation exercise are also covered now as 5S is a powerful starting point for Lean transformation.

Plant tours are organised within the first two days. These are usually of participants plants where some aspects of Lean that are already in progress are displayed to other participants. Where necessary, tours of other plants in the SELF network are organised. A review of the participants observations takes place after each tour.

Kanban techniques are then explained and their applicability to the various participant companies discussed. The Quick-change-over (SMED) module includes a video-bsed exercised in which participants are shown a 15 min video of a real change-over, asked to analyse it using stopwatches and asked for their improvement suggestions. A further video of the improved changeover is shown, incorporating various improvements, many of which they may have suggested themselves.

A minitest is given in Day 3, comprising about 10 MCQ questions to verify the effectiveness of the learning process. Answers to all questions are reviewed with the class so that common areas of confusion can be cleared up.

The Standard Work module includes a further simulation exercise in which participants again get to practice observing and timing their fellow participants performing a simulated repetitive manufacturing operation with a view to improving and standardising it. Such practice is crucial to being comfortable with doing such work in their own plants.

The topics of Kaizen Blitz Workshops and Value Stream Mapping are dealt with at the end, since they both require an understanding of the previous tools. The VSM exercise involves participants creating a Current state VSM for a selected product family in one of the plants, reviewing it and suggesting a Future State VSM.

There is a final review both of the course and of the project progress with each participant, so that they have a clear workplan for their project and clear understanding of the expected extent of their project for the purposes of Certification. 

The training is evaluated in several ways:

1.         Immediate feedback questionnaire on the final day. (Level 1-Reaction)

2.         Assignment and Value Stream Map exercise.

3.         Participant questionnaire about 1 month after completion (Level 2-Assess the Learning)

4.         Training Impact questionnaire completed by participants supervisor approx 1 month after course completion (Level 3 –Impact on the Job)

5.         Project review max 3 months after course completion.