Lean Manufacturing Tools

Transcription

1 The Further Education and Training Awards Council (FETAC) was set up as a statutory body on 11 June 2001 by the Minister for Education and Science. Under the Qualifications (Education & Training) Act, 1999, FETAC now has responsibility for making awards previously made by NCVA. Module Descriptor Lean Manufacturing Tools Level 5 L

2 1 Module Title Lean Manufacturing Tools 2 Module Code L Level 5 4 Credit Value 1 credit 5 Purpose This module is a statement of the standards to be achieved to gain a FETAC credit in Lean Manufacturing Tools at Level 5. This module provides the learner with many of the tools to transform their manufacturing organisation into a leaner and more competitive enterprise. The module is designed to give the learner a detailed knowledge of how to use tools such as 5S Workplace Organisation, Kanban, SMED, Standard Work and Mistake-proofing. 6 Preferred Entry Level 7 Special Requirements Level 4 Certificate, Leaving Certificate or equivalent qualifications and/or relevant life and work experiences. None. 8 General Aims Learners who successfully complete this module will: 8.1 Conduct Lean improvement activities in their own area of responsibility 8.2 Assist senior management in implementing Lean Principles in a wider manufacturing environment 2

3 9 Units The specific learning outcomes are grouped into nine units. Unit 1 Unit 2 Unit 3 Unit 4 Unit 5 Unit 6 Unit 7 Unit 8 Unit 9 Lean Thinking Lean Level 3s (5S, Visual Control, TPM, OEE) Improvement Cycles Lean Material Systems & Kanban Quick Changeovers (The SMED System) Takt Time & Standard Work Kaizen events Value Stream Mapping Quality, Mistake Proofing, Line Layout 10 Specific Learning Outcomes Unit 1 Lean Thinking Distinguish between Value-Added and Non-value-added activities in their own organisations Describe each of the Seven Wastes Describe the key differences between Lean Manufacturing and Mass Production List the Five Lean Principles. Unit 2 Lean Level 3s List the benefits of good Workplace Organisation Describe the 5 steps of 5S Workplace Organisation Define appropriate Visual Control systems List the benefits of Total Productive Maintenance (TPM) Describe the elements of the Overall Equipment Effectiveness (OEE) metric Describe a basic Total Productive Maintenance (TPM) system to improve Overall Equipment Effectiveness (OEE). 3

4 Unit 3 Improvement Cycles Select the appropriate improvement tool Distinguish between Root causes, Direct causes and Contributing causes Identify appropriate Corrective & Preventive actions Construct a Problem Definition and SMART objectives Distinguish between Incremental and Breakthrough Improvement. Unit 4 Lean Material Systems and Kanban Select an appropriate Kanban system Perform basic calculations of number of kanban cards required List the benefits of a Timed Delivery route. Unit 5 Quick Changeovers (The SMED System) Describe the four stages of the SMED Technique Reduce Changeover time using SMED. Unit 6 Takt Time & Standard Work Describe the elements of Standard Work Conduct Process Observation to determine element cycle times Configure Standard Work for minimum use of labour, materials and equipment Document the results on a Standard Work Chart. 4

5 Unit 7 Kaizen Events Identify appropriate situations for a Kaizen Event Select appropriate team-members Identify goals for an event Successfully participate in a Kaizen Event. Unit 8 Value Stream Mapping Document the current status using a Current State Value Stream Map Develop a Future State Value Stream Map, describing desired improvements. Unit 9 Quality, Mistake-proofing and Line Layout Explain the interaction between quality and lean manufacturing Select appropriate mistake-proofing devices Select or devise an appropriate line layout. 5

6 11 Portfolio of Assessment. Summary Assignment 25% Skills Demonstration (VSM) 25% Project 50% 11.1 Assignment 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 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 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 6

7 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. 12 Grading Pass 50-64% Merit 65-79% Distinction % 7

8 Individual Candidate ing Sheet 1 Lean Manufacturing Tools L22586 Assignment 25% Candidate Name: PPSN: Centre: Centre No.: Assessment Criteria Maximum Candidate Concise statement of current use of Lean tools 5 Clear indication of the scope for improvement 10 Clear understanding of Lean Principles 10 TOTAL MARKS This mark should be transferred to the Module Results Summary Sheet 25 Internal Assessor s Signature: Date: External Authenticator s Signature: Date: 8

9 Individual Candidate ing Sheet 2 Lean Manufacturing Tools L22586 Skills Demo 25% Candidate Name: PPSN: Centre: Centre No.: Assessment Criteria Accurate use of Value Stream Mapping tool in Current State VSM Maximum 10 Candidate Practical & appropriate solutions in the Future State VSM 5 Solutions based on Lean Principles & Tools 5 Clarity of Presentation of issues and the proposed solutions 5 TOTAL MARKS This mark should be transferred to the Module Results Summary Sheet 25 Internal Assessor s Signature: Date: External Authenticator s Signature: Date: 9

10 Individual Candidate ing Sheet 3 Lean Manufacturing Tools L22586 Project 50% Candidate Name: PPSN: Centre: Centre No.: Assessment Criteria Is the scope commensurate with the participant s role & responsibility within the company? Maximum 5 Candidate Can the candidate list 3 lean tools used in the project? 5 Does this candidate understand the tools used? Has the candidate identified problems, their root causes and possible solutions? 10 Did this candidate provide some creative solutions? Can & have the benefits of this project been measured? Has the candidate identified further steps that can be taken? TOTAL MARKS This mark should be transferred to the Module Results Summary Sheet Internal Assessor s Signature: Date: External Authenticator s Signature: Date: 10

11 FETAC Module Results Summary Sheet Module Title: Lean Manufacturing Tools Module Code: L22586 Sheet 1 Sheet 2 Sheet Candidate Surname Candidate Forename Sheet 3 Total 100% Grade* Signed: Internal Assessor: Date: This sheet is for internal assessors to record the overall marks of individual candidates. It should be retained in the centre. The marks awarded should be transferred to the official FETAC Module Results Sheet issued to centres before the visit of the external Authenticator. Grade* D: % M: 65-79% P: 50-64% U: 0-49% W: candidates entered who did not present for assessment 11