Applying continuous improvement techniques to aeronautical Overview This unit identifies the competences you need for applying continuous improvement techniques (Kaizen) to aeronautical engineering work activities, in accordance with approved procedures. It involves benchmarking the process before and after the Kaizen activity, in order to set quantifiable objectives and targets for the improvement activity. The activities undertaken will include the identification of all forms of waste, and the problems or conditions within the work area or activity where improvements can be made. You will need to focus on improvements which would give reduced product cost, improved safety, improved quality, improvements to working practices and procedures, reduction in lead time and reduction/elimination of waste. You will also be required to conduct continuous improvement activities, which may include data collection through key performance indicators (KPIs), contributing to or improving existing standard operating procedures (SOPs), which include maintenance of equipment, health and safety practices and procedures, process procedures, manufacturing operations and quality improvements. You will be required to demonstrate that improvements have been effective through recalculation of KPIs, following the continuous improvement activities. Your responsibilities will require you to comply with organisational policy and procedures for the activities undertaken, and to report any problems with these activities that you cannot personally resolve, or that are outside your permitted authority, to the relevant people. You will be expected to work with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out. Your underpinning knowledge will provide a good understanding of the Kaizen activity, and the area in which you are working, and will provide an informed approach to the methods, techniques and procedures used. You will understand the Kaizen principles and their application, in adequate depth to provide a sound basis for carrying out the activities to the required criteria. You will understand the safety precautions required in the area where the Kaizen activity is taking place. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace. SEMAE3-197 1
Performance criteria You must be able to: P1 work safely at all times, complying with health and safety and other relevant regulations and guidelines P2 provide comparisons of the process before and after the continuous improvement activity (to confirm improvements) P3 apply the principles and process of the continuous improvement activity P4 contribute to the identification of quantifiable objectives and targets for the continuous improvement activity P5 carry out the continuous improvement activity within the chosen work area/activity P6 identify waste, problems or conditions within the work area or activity where improvements can be made P7 contribute to the production and/or updating of standard operating procedures (SOPs), that sustain the improvements made, resulting from the continuous improvement activity P8 demonstrate the effectiveness of any continuous improvement activities by using data and key performance indicators (KPIs) SEMAE3-197 2
Knowledge and understanding You need to know and understand: K1 the health and safety requirements of the area in which you are carrying out the business improvement activity K2 the importance of wearing protective clothing and other appropriate safety equipment in hazardous or clean area environments, when carrying out the continuous improvement activities K3 how a work area/activity is selected for the business improvement activity K4 the principles and process for the deployment of business improvement K5 the `six hidden losses' and `seven wastes', and how to identify and eliminate them K6 problem solving and root cause analysis K7 the importance of understanding the process/activity under review, and how this will affect the quality of the problem solving K8 how to carry out a business improvement activity and establish measurable improvements K9 how to distinguish facts from opinions in order to identify improvement actions K10 how improvements to the process are achieved by engaging the knowledge and experience of the people examining the process K11 why you must not blame the people who have identified the potential improvements K12 how to evaluate improvement ideas in order to select those that are to be pursued K13 how to set quantifiable targets and objectives K14 how to create standard operating procedures (SOPs) K15 the techniques used to visually communicate the work of the business improvement activity to participants and others K16 how to use a variety of presentation methods, in appropriate combination (such as verbal, verbal/written combinations) K17 the application of the eight lean manufacturing key performance indicators (right first time, people productivity, stock turns, delivery schedule achievement, overall equipment effectiveness, value added per person, floor space utilisation, product cost reduction) K18 the organisational reporting processes and procedures to be observed K19 the extent of your own authority and to whom you should report in the event of problems that you cannot resolve SEMAE3-197 3
Additional Information Scope/range related to performance criteria You must be able to: 1. Apply continuous improvement techniques and procedures to two of the following aeronautical : 1.1 drawing/design activities (such as electronic components, printed circuit boards, thick, thin or flexible film circuits) 1.2 manufacturing activities (such as machining, detail fitting, fabrication of components, moulding) 1.3 mechanical assembly activities (such as mechanical, structural, fluid power) 1.4 electrical/electronic assembly activities (such as avionic) 1.5 installation activities (such as mechanical equipment installation, electrical/avionic installation) 1.6 lifting and moving large components/assemblies (including transportation/delivery) 1.7 finishing activities (such as stripping finishes, painting, plating, anodising) 1.8 material processing activities (such as heat treatment, annealing) 1.9 modifications and repair activities (such as airframe, systems, avionics) 1.10 materials handling (such as movement of materials, materials storage, removal of waste) 1.11 operational activities (such as quality systems and audit, scheduled safety audits and risk assessments) 1.12 maintenance activities (such as planned preventive maintenance, part/sub-assembly exchange, breakdown response, maintenance records systems, line setting) 1.13 equipment capability/performance measurement 1.14 plant and equipment (such as plant layout, equipment changeover, equipment replacement) 1.15 testing and trialling 1.16 commissioning/decommissioning 1.17 research and development 2. Identify improvements within the working area/activity, which cover three of the following: 2.1 reduced product cost 2.2 improved delivery schedule adherence 2.3 reduction in waste 2.4 improved safety 2.5 improvements to working practices 2.6 improved quality 2.7 reduction in lead time 3. Produce and/or contribute to the identification of improvements in existing standard operating procedures, which cover three of the SEMAE3-197 4
following: 3.1 health and safety 3.2 manufacturing operations 3.3 cleaning of equipment 3.4 process procedures 3.5 quality improvements 3.6 maintenance of equipment 4. Identify and/or determine and monitor three of the following key performance indicators: 4.1 non right first time (parts per million ppm) 4.2 stock turns 4.3 overall equipment effectiveness (OEE) 4.4 value added per person 4.5 delivery schedule adherence 4.6 floor space utilisation 4.7 people productivity SEMAE3-197 5
Developed by SEMTA Version number 1 Date approved December 2008 Indicative review date Validity Status Originating organisation December 2014 Current Original SEMTA Original URN 197 Relevant occupations Engineering Professionals; Engineering and manufacturing technologies; Engineering; Science and Engineering Technicians Suite Aeronautical Engineering Suite 3 2008 Key words improvement techniques (Kaizen), aeronautical,, data collection, key performance indicators (KPIs), standard operating procedures (SOPs) SEMAE3-197 6