Manufacturing

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.

Skill 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 minutes 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.

Plant tour
Review of tour

Day 2 - Improvement cycles: Breakthrough vs incremental, PDCA, Root Cause Analysis, DMAIC.
Problem Definition, Team Charter & SMART Objectives
5S Workplace Organisation & Numbers simulation.

Plant tour
Review of Tour

Day 3 - Making Material Flow
Kanban
SMED Quick Changeovers & video-based exercise.
Mistake proofing, Poka-yoke
Minitest.

Review of project scopes & progress.

Day 4 - Std Work, Load–cycletime charts & Duplotronic exercise
Takt time & exercises
Layout & line design
Team work, Groupthink
Managing change

Day 5 - OEE & TPM
Kaizen Blitz Workshops
Minitest
Thought process mapping
VSM, Current state, Future state
VSM exercise in selected plant.

Project reviews and workplan:

Course review
Project mentoring days (if required)
Presentation of Project Results

Day 3 Adobe Photoshop / Adobe Bridge
On Day 3 Participants will learn to use Adobe Photoshop (the industry standard image editing application) to resize and check the images they will be using in there printed files. They will develop an understanding of colour modes, resolution and colour profiles and become aware of how these settings carry through into their layout application (Indesign), and the need for these specifications and formatting within the print documents they create.

Day 4 Practical Design & Layout
On Day 4 Participants will work with Indesign and Photoshop combined on the Design and Layout of a 16 page A5 Booklet which will go to press on Day 5.

Day 5 On Site
On Day 5 the Participants will visit a Dublin print shop to experience the Production Process through its various stages: Booking the job in, Costing the job, The receipt of the Art Work, The journey the Artwork takes from the Artwork department through flight check, Rip to the Separations and Plate making. Seeing the Job onto the Machine for Print and through to finishing and packaging.

Hopefully we will be able to offer a short placement within a company in the Dublin area TBC.