Manufacturing improvement training services

Manufacturing Improvement Training

Below are examples of the training modules we can use to put together a bespoke training package to meet your specific Manufacturing & Improvement needs. Use these as a guide to aid you in identifying area’s in which you wish to develop your people.

Introduction to Lean and Short Interval Control (what, why, when) - (2 Hours)

On completion of this module you will be able to:

• Understand What the Term "Lean manufacturing" refers to.
• Understand how Lean principle's can drive improvements in your business.
• List some of the "off the shelf" Improvement packages.
• Explain what is meant by the term SIC.
• Understand how SIC should be used and the data required.

• Know what the terms NME & APQ mean.
• Understand what NME is and what it measures.
• Know which data from the SIC is relevant to working out NME.
• Be able to calculate a basic "good" NME %.
• List the six main losses in manufacturing.
• Understand how the six losses relate to APQ losses.
• Use calculations to split the "bad" NME into APQ losses.
• Analyze basic data graphs showing NME and APQ to determine problem areas in manufacturing.
• Understand what the terms GME and OEE mean and how they differ to NME.

• Know what Productivity is measuring.
• Know which data from the SIC is relevant to working out productivity.
• Understand the importance of standards in manufacturing.
• Explain what the main standards are and what they are used for.
• Be able to work out productivity standards.
• Understand the terms SMV & AMV.
• Be able to calculate productivity.
• Be able to calculate productivity losses.
• Know how the productivity losses relate to APQ losses.

• Understand how raw SIC data affects DWOR data.
• Be familiar with examples of DWOR reports and what they represent.
• Using DWOR data to pin-point area's for improvement.
• Communicate this information to colleagues through a cell review.
• Use a cell review to form actions to solve problem areas in manufacturing.

• Be able to define the term Kaizen.
• Understand the 2 types of Kaizen.
• List the steps to holding a Kaizen event, this will include:
• Selecting members of the team.
• Holding effective Kaizen meetings.
• Understanding the "Current State".
• Presenting an action plan.
• Importance of measuring performance against objectives.
• How to say "thank you".
• Understand the Kaizen Loop.

• Understand what the 5S's are.
• Recognize bad examples of GWP.
• Consider how to implement 5S in your workplace assertively.
• Own some tools to measure current levels of GWP, and identify areas for improvement.
• Suggest solutions using 5S methodology towards manufacturing issues.
• Understand the benefits of 5S in the workplace.
• Consider a 6th "S".

• Know what Value Added and Non Value Added means.
• Understand what Necessary Non Value Added means.
• Know what activities constitute each of these.
• Understand what implication these have on KPI's.
• List the 7 wastes in manufacturing.
• Name examples of each of the wastes in your work areas.
• Identify VA, NVA & NNVA activities and wastes in a real work environment.
• Have tools available to you to identify areas of waste and loss and make suggestions for areas of improvement.

• Know what happens before define.
• Understand what DMIAC means and why it is used.
• Understand what is required at each stage of DMAIC.
• Use SIPOC process diagrams.
• Create a VSM.
• Use Measurement as a tool (process observation, time value maps, pareto charts, time series plots, the challenges of data collection).
• Use cause and effect diagrams.
• Use scatter plots.

• Define SMED.
• Understand how to Approach SMED.
• Identify changeover as an area for improvement from statistical data.
• Understand the impact of poor changeovers on productivity, APQ losses and NME.
• Understand what a change over is.
• Understand the impact of poor changeover.
• Identify poor changeover practise.
• List the 5 steps to changeover reduction (SMED).
• Continuing good practise.

• Define line balancing.
• Understand what impact a line balance has on productivity.
• Identify a poorly balanced line and why.
• Perform a line balance through a classroom activity.
• Consider all possibilities of a line balance.
• Create a line plan to maximise productivity.
• Measuring performance.
• How to implement the line plan "assertively".
• Communicating requirements to team.
• Following up a line balance.
• (If possible) A "go see" activity on factory floor.

• Understand what takt time means.
• Why use takt time.
• Be able to calculate takt times.
• The benefits of calculating takt time.
• Understand what cycle times are.
• Know why cycle times would be recorded.
• The benefits of using Kanban.
• Where you can and cannot use Kanban.
• The basic Kanban rules.
• Understand the 3 different types of Kanban.
• Implement a simple Kanban system & use takt times to predict production time (Simulation).

• Understand who are the right people.
• Pick the right projects.
• Follow the method.
• Understand the need to have clearly defined roles and responsibilities.
• Understand why communication is so vital to the success of your project.
• Explain why and how to gain support from your project team.

• Understand what FMEA is.
• Understand why we use FMEA.
• Know when to use FMEA.
• Understand the different types FMEA.
• Understand FMEA's link with Continuous Improvement.
• Use FMEA tools to identify areas of failure and the effects.
• Use ranking to determine severity of failure.
• Recognise potential applications of FMEA.
• Know the steps on completing FMEA.