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 L22586 www.fetac.ie
1 Module Title Lean Manufacturing Tools 2 Module Code L22586 3 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
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 10.1.1 Distinguish between Value-Added and Non-value-added activities in their own organisations 10.1.2 Describe each of the Seven Wastes 10.1.3 Describe the key differences between Lean Manufacturing and Mass Production 10.1.4 List the Five Lean Principles. Unit 2 Lean Level 3s 10.2.1 List the benefits of good Workplace Organisation 10.2.2 Describe the 5 steps of 5S Workplace Organisation 10.2.3 Define appropriate Visual Control systems 10.2.4 List the benefits of Total Productive Maintenance (TPM) 10.2.5 Describe the elements of the Overall Equipment Effectiveness (OEE) metric 10.2.6 Describe a basic Total Productive Maintenance (TPM) system to improve Overall Equipment Effectiveness (OEE). 3
Unit 3 Improvement Cycles 10.3.1 Select the appropriate improvement tool 10.3.2 Distinguish between Root causes, Direct causes and Contributing causes 10.3.3 Identify appropriate Corrective & Preventive actions 10.3.4 Construct a Problem Definition and SMART objectives 10.3.5 Distinguish between Incremental and Breakthrough Improvement. Unit 4 Lean Material Systems and Kanban 10.4.1 Select an appropriate Kanban system 10.4.2 Perform basic calculations of number of kanban cards required 10.4.3 List the benefits of a Timed Delivery route. Unit 5 Quick Changeovers (The SMED System) 10.5.1 Describe the four stages of the SMED Technique 10.5.2 Reduce Changeover time using SMED. Unit 6 Takt Time & Standard Work 10.6.1 Describe the elements of Standard Work 10.6.2 Conduct Process Observation to determine element cycle times 10.6.3 Configure Standard Work for minimum use of labour, materials and equipment 10.6.4 Document the results on a Standard Work Chart. 4
Unit 7 Kaizen Events 10.7.1 Identify appropriate situations for a Kaizen Event 10.7.2 Select appropriate team-members 10.7.3 Identify goals for an event 10.7.4 Successfully participate in a Kaizen Event. Unit 8 Value Stream Mapping 10.8.1 Document the current status using a Current State Value Stream Map 10.8.2 Develop a Future State Value Stream Map, describing desired improvements. Unit 9 Quality, Mistake-proofing and Line Layout 10.9.1 Explain the interaction between quality and lean manufacturing 10.9.2 Select appropriate mistake-proofing devices 10.9.3 Select or devise an appropriate line layout. 5
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. 11.2 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. 11.3 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 6
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 80 100% 7
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
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
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 50 10 5 10 5 Internal Assessor s Signature: Date: External Authenticator s Signature: Date: 10
FETAC Module Results Summary Sheet Module Title: Lean Manufacturing Tools Module Code: L22586 Sheet 1 Sheet 2 Sheet 25 25 50 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: 80-100% M: 65-79% P: 50-64% U: 0-49% W: candidates entered who did not present for assessment 11