Skills Portfolio 2010

SKILLS PORTFOLIO

2010

CONTENTS

NVQ Training:

Business Improvement Techniques Level 2 Business Improvement Techniques Level 3 Lean Office Level 2 Performing Manufacturing Operations Plus Level 2 Performing Engineering Operations Level 2 Warehousing & Storage Plus Level 2 Business & Administration Level 2 Customer Service Level 2 Information Technology Qualification Level 2 Team Leader

Apprenticeships:

Customer Service Business & Administration Information Technology Qualification Performing Manufacturing Operations Performing Engineering Operations Warehousing & Storage

Rapid Improvement Workshops:

5S & Workplace Organisation – 1 day Kaizen & Continuous Improvement – 1 day FMEA (Failure Mode Effect Analysis – 1 day Introduction to Lean – 1 day Introduction to Lean – 2 day Introduction to Lean – 5 day The Lean Leader Programme (Level 3) Management to Leadership

Case Studies / Testimonials

NVQ TRAINING

Business ImprovementTechniques (BIT)“Productivity”, “Lean Thinking”, “Continuous Improvement” and “Waste” - all these terms are synonymous with the Manufacturing and Engineering sector.

The reality is that manufacturing organisations have struggled for decades in a highly competitive environment to reduce defects and waste whilst battling to create optimum flow by using Lean principles. With more pressure on companies than ever before, these tools are now being adopted on a wider scale. The Public and Service sectors are using them increasingly to help reduce costs, whilst ultimately achieving more value for their customers.

The BIT that counts

BIT explores the concept of continuous improvement and demonstrates how eliminating waste, reducing variation and preventing defects can dramatically improve business performance. From the Japanese 5S method to the Kaizen approach, the programme covers the most up-to-date management thinking. Delivered at your workplace, the programme sees your employees implementing improvement projects on your shop floor.

We have successfully rolled out this programme in the Manufacturing, Engineering, Public and Service sectors, so are uniquely aware of its application for all.

Programme Information

Benefits:

• Provenproductivity improvement model

• Phasedandstructuredapproach

• Accreditedagainsta national standard

• Deliverimproved workforce capability

• Increases“cando”and “know how”

• Sustainablethroughchampions

• Quantifiedmonetarysavings are created as part of the BIT programme

/// We also offer programmes in Management Development /// Visit www.businessimpactuk.com tofindoutmore///

Programme Framework

NVQ Diploma in Business Improvement Techniques Level 2

Induction enrolment: Covering completion of ILP, literacy and numeracy assessments, BIUK policies and procedures. Equality and Diversity and Safeguarding also introduced. 2.5 hours.

UPK 1: Covering, 5S workplace organisation, Health and Safety, Visual Management, and Team working. 4 hours.

UPK 2: Covering, Kaizen, Health and Safety, Team working, Problem Solving, Data collection and analysis. 4 hours.

UPK 3: Covering, Health and Safety, Kaizen, Problem Solving, Data collection and Analysis. 4 hours.

Improvement activity 1 Shop floor application session. 8 hours.

Improvement activity 2 Shop floor application session. 8 hours

Improvement activity 3 Shop floor application session. 8 hours.

Business ImprovementTechniques (BIT) Level 3

Following on from level 2, this Business Improvement Techniquesquali�cation at level 3 is designed for managers, supervisors and other sta� who have an important role to play in the business. . The quali�cation enables these individuals to develop the skills they need to be able to act as continuous improvement facilitators

within the organisation and lead improvement projects.

The quali�cation includes training in the following areas: Leading E�ective TeamsApplying Problem Solving Techniques Creating and Maintaining Standard Operating Procedures

Plus an additional unit from the following to be selected in line with company needs:

Flow Process Analysis SMED (a waste reduction tool to assist rapid changeover) TPM (Total Productive Maintenance) The training is followed by three facilitated improvement project days where the team utilise the methods they have learned during the training to create and analyse process maps, identify suitable improvement projects on the shop�oor and implement those improvements.


• Reduce costs, variation and waste

• Improve business performance

•

• Helps reduce workplace accidents

• Achieve results with minimal disruption to operations

• Improved sta� morale

/// Management Development /// Visit www.businessimpactuk.com to out more ///

Maximise pro�ts and revenues

BIT LEVEL 3 PROCESS FLOW

UPK 1. 8 Hours. Leading Teams, P/Solving, SMED

techniques.

UPK 2. 4-8 Hours. SMED techniques

continued and SOPs.

Facilitated

Improvement Session 1.

Facilitated


Facilitated


Follow up and

close out session.

Individuals to lead a 5’S activity and close

out actions from Improvement 1.

Individuals to lead a 5’S activity and close

out actions from Improvement 2.

Individuals to lead a 5’S activity and

close out actions from Improvement

3.

Lean OfficeWhile many organisations have successfully applied the principles of Lean Manufacturing to the factory floor, often companies overlook the benefits that streamlining administrative functions can deliver to the bottom line… and to customer service.

Typically some 60% – 80% of all costs related to a product are non-production costs, but due to lack of understanding in the identification and monitoring of value-add in non-manufacturing (identifying value is a crucial first step on the road to improvement), businesses fail to address many important issues. By focusing on the end-to-end process it can become clear that, despite making significant improvements in the process, often the overall lead-time has improved very little.

The Business Improvement Techniques (NVQ) qualification is designed to assist organisations in improving their business activities by applying the tools and techniques of continuous improvement. Business Impact have adapted this hugely successful qualification and adjusted the focus to reflect the back office and administrative support functions to address areas such as:

1. Workplace Organisation 2. The identification and elimination of waste3. Operational effectiveness 4. Teamwork and communication 5. Improvement and productivity

This programme is designed to ensure that all activities add value and are sustainable, impacting on Quality, Cost and Delivery performance that:

• Eliminates the risk of a poor service reaching the customer • Reduces operational costs • Improves profitability and competitiveness


/// We also offer programmes in Management Development /// Visit www.businessimpactuk.com to find out more ///

Benefits to the employers:

• Improvedbusinessperformance to assist in winning contracts

• Reductionincostsandwaste

• Increasedprofitsandrevenues

• Reductioninworkplaceaccidents

• Improvedstaffmorale and performance

Programme Framework:

Lean Office Level 2

Induction / Enrolment – The Lean Office Qualification

Individual Learning Plan (ILP) Numeracy & Literacy Assessment

Analysis of Training Needs Introduction to the Lean Office Qualification

UPK Session 1 – Health & Safety + Teamwork HASAWA 1974

Health & Safety in the Office Manual Handling and COSHH

Risk Assessment Teamwork and Team Roles

UPK Session 2 – Workplace Organisation The Working Environment

Structured Workplace Organisation Auditing the Work Area

Visual Management Systems Workplace Visual Management Opportunities

UPK Session 3 – Continuous Improvement Continuous Improvement

Work and Waste (The Eight Wastes) Analysing the Work Process

Key Performance Indicators (KPI’s) Matching Work Level to Customer Demand

UPK Session 4 – Problem Solving & Standardisation of Work

Cause & Effect Analysis Identifying Underlying Causes

Selecting Solutions Standard Work Practises

Office Ergonomics

Improvement Activity x 3 – Quality, Cost & Delivery Area Risk Assessment

Workplace Organisation Audit (Pre & Post) Data Gathering and Problem Definition

Underlying Cause Identification Solution Generation

Improvement Proposal Record of Area Status before Improvement

Improvement Implementation Record of Area Status after Improvement

Improvement Close Out & Action Plan


Performing Manufacturing Operations Plus (PMO Plus)

Benefits:

Buy into best methods of working from employees and maybe a starting point for a learning journey

Opportunity to participate in

a 5S work based improvement project

Costs:

Time off the job

Fully funded qualification for 1st Level 2 and partially funded for 2nd Level 2

The Performing Manufacturing Operations NVQ Level 2 is primarily for confirming the competence of existing employees and for ensuring standardised working/audit compliance. Confirmation of competence is Assessed via a series of on the job observations by a Business Impact Assessor and carried out on normal shift patterns at the place of work. For this qualification it is essential that staff can perform manufacturing operations and would normally do so on a daily basis. By observing and having dialogue the Assessor captures written evidence for example: wearing the correct PPE and awareness of the H&S requirements; housekeeping is in order; knows what to do if a non-conformance could or has occurred; good understanding of the process and any variables. At the end of each observation the Assessor will share the written feedback with your employee and they have the opportunity to amend and review along with the Team Leader. Any necessary actions are agreed prior to the next observation. Employees will also participate in a half day 5S work based improvement project for their area. Time off the job: 2 hour enrolment session/induction, then 3 on the job observations/assessments each with a 20 minute review. 4 hours for the improvement project. Considerations: maximum group size of 12 for the enrolment session; short refresher training as part of induction?

PERFORMING MANUFACTURING OPERATIONS NVQ L2 PROGRAMME


Enrolment/Induction

2 hours Group size c.12

Option for Training

Session: 5S & basic audit improvement

2-4 hours

1st on the job assessment & observation

Includes 20 minute 1:1 & agreed actions for next

observation

2nd on the job assessment and observation

Includes 20 minute 1:1 & agreed actions for the next

observation

3rd on the job assessment and observation

Includes 20 minute 1:1 to confirm all actions have

been completed

Certification of Achievement


Performing Engineering Operations

Benefits:

Allows individuals the opportunity to gain skills and recognition in the area in which they work

Ensures your organisation

has competent personnel who can perform skills to industry standards

Costs:

Time off the job


The Performing Engineering Operations NVQ Level 2 is primarily for confirming the competence of existing employees and for ensuring standardised working/audit compliance. Confirmation of competence is assessed via a series of on the job observations by a Business Impact Assessor and carried out on normal shift patterns at the place of work. For this qualification it is essential that staff can perform engineering operations and would normally do so on a daily basis. By observing and having dialogue the Assessor captures written evidence for example: wearing the correct PPE and awareness of the H&S requirements; housekeeping is in order and knows what to do if a non-conformance could or has occurred; At the end of each observation the Assessor will share the written feedback with your employee and they have the opportunity to amend and review along with the Team Leader. Any necessary actions are agreed prior to the next observation. Time off the job: 2 hour enrolment session/induction, then 3 on the job observations/assessments each with a 20 minute review. Considerations: maximum group size of 12 for the enrolment session.

PERFORMING ENGINEERING OPERATIONS NVQ L2 PROGRAMME


Enrolment/Induction


1st on the job assessment

& observation Includes 20 minute 1:1 & agreed actions for next

observation

Option for Training Session: 5S & basic audit

improvement 2-4 hours



observation



been completed

Professional Discussion

with candidate and review of product evidence

Witness testimony taken

from candidates’ line manager to confirm

competence

Certificate of achievement


Warehousing & Storage Plus (WAS Plus)

Benefits:

Buy into best methods of working from employees and maybe a starting point for a learning journey

Opportunity to participate in

a 5S work based improvement project

Costs:

Time off the job


The Warehousing & Storage NVQ Level 2 is primarily for confirming the competence of existing employees and for ensuring standardised working/audit compliance. Confirmation of competence is Assessed via a series of on the job observations by a Business Impact Assessor and carried out on normal shift patterns at the place of work. For this qualification it is essential that employees perform a full cycle of activity from orders to picking/packing to dispatch. By observing and having dialogue the Assessor captures written evidence for example: wearing the correct PPE and awareness of the H&S requirements particularly in relation to Fork Lift Trucks, stacking etc.; housekeeping is in order; knows what to do if a non-conformance could or has occurred; good understanding of the process and any variables. At the end of each observation the Assessor will share the written feedback with your employee and they have the opportunity to amend and review along with the Team Leader. Any necessary actions are agreed prior to the next observation. Employees will also participate in a half day 5S work based improvement project for their area. Time off the job: 2 hour enrolment session/induction, then 3 on the job observations/assessments each with a 20 minute review. 4 hours for the improvement project. Considerations: maximum group size of 12 for the enrolment session; short refresher training as part of induction?


WAREHOUSING & STORAGE OPERATIONS NVQ L2 PROGRAMME

Enrolment/Induction


Option for Training

Session: 5S & basic audit improvement

2-4 hours

1st on the job assessment & observation

Includes 20 minute 1:1 & agreed actions for next

observation



observation



been completed

Certification of Achievement


Business and Administration

Benefits:

Improved time management

Increased productivity

A reduction in administrative errors

Costs:

Time off the job

Fully funded qualification for 1st

Level 2 and partially funded for 2nd Level 2

The Business and Administration NVQ Level 2 is primarily for confirming the competence of existing employees and for ensuring standardised working/audit compliance. Confirmation of competence is assessed via a series of on the job observations by a Business Impact Assessor and carried out on normal shift patterns at the place of work. For this qualification it is essential that staff can perform administrative duties and would normally do so on a daily basis. By observing and having dialogue the assessor captures written evidence, for example: health and safety, working effectively with others, producing documents, processing customer transactions and researching and reporting information.. At the end of each observation the assessor will share the written feedback with your employee and they have the opportunity to amend and review, along with the Team Leader. Any necessary actions are agreed prior to the next observation. Time off the job: 2 hour enrolment session/induction, then 6 on the job observations/assessments each with a 20 minute review


Customer Service

Benefits:

Consistent delivery of customer service excellence within your organisation

Customer queries are dealt

with quickly and resolved effectively

Costs:

Time off the job


The Customer Service NVQ Level 2 is primarily for confirming the competence of existing employees and for ensuring standardised working/audit compliance. Confirmation of competence is assessed via a series of on the job observations by a Business Impact Assessor and carried out on normal shift patterns at the place of work. For this qualification it is essential that staff can perform customer service duties and would normally do so on a daily basis. By observing and having dialogue the assessor captures written evidence, for example: communicating with customers, promoting additional services or products, processing customer service information, delivering customer service excellence and dealing with customer queries effectively. At the end of each observation the assessor will share the written feedback with your employee and they have the opportunity to amend and review, along with the Team Leader. Any necessary actions are agreed prior to the next observation. Time off the job: 2 hour enrolment session/induction, then 6 on the job observations/assessments each with a 20 minute review


Information Technology Qualification

Benefits:

Evaluating the impact of ICT

Developing new tools and techniques

Costs:

Time off the job

Fully funded qualification for 1st Level 2 and partially funded for 2nd Level 2.

The ITQ NVQ Level 2 is primarily for confirming the competence of existing employees and for ensuring standardised working/audit compliance. Confirmation of competence is assessed via a series of on the job observations by a Business Impact Assessor and carried out on normal shift patterns at the place of work. For this qualification it is essential that staff can perform ICT functions and do so, on a daily basis. By observing and having dialogue the Assessor captures written evidence for example: Using IT systems, using IT to exchange information, word processing and the use of database software. At the end of each observation the Assessor will share the written feedback with your employee and they have the opportunity to amend and review along with the Team Leader. Any necessary actions are agreed prior to the next observation. Time off the job: 2 hour enrolment session/induction, then 5 on the job observations/assessments each with a 20 minute review.

Introductory Award in Team LeadingThe introductory award in team leading is designed as a starting point for aspiring team leaders or those who are new to a team leading role. The programme gives learners a basic knowledge of the various roles, functions and responsibilities of a team leader.


/// We also offer programmes in Workforce Development /// Visit www.businessimpactuk.com to find out more ///

Certificate in Team Leading The Level 2 Certificate in Team Leading programme comprehensively covers the full range of responsibilities of the team/group leader or member, and can be tailored to fit your specific needs. The certificate develops leaders and managers within the national qualifications framework.

The full Certificate consists of an induction, four 15-hour modules plus tutorial support. The modular route reinforces the commitment to short, sharp, flexible learning to ensure an exact fit with individual candidate needs and workplace requirements.

Team Leading NVQ Level 2 The Level 2 NVQ in Team Leading is designed for team leaders who are primarily concerned with motivating their team members and achieving agreed outputs, with limited authority for deploying resources. Flexibility is achieved through optional units, which complement the four mandatory units designed to develop the core competences needed by today’s team leaders.

APPRENTICESHIPS


Customer Service Apprenticeship

Framework:

9 month programme

NVQ L2 in Customer Service

Functional Skills in Maths, English & ICT

Certificate in Customer Service

Employment Rights & Responsibilities

Costs:

Fully funded for all learners aged 16-24

The Apprenticeship Framework: The framework is made up of four elements:

NVQ L2 in Customer Service Functional Skills in Maths, English & ICT Certificate in Customer Service Employment Rights & Responsibilities

It is a 9 month programme and all elements must be completed in order to achieve an apprenticeship in Customer Service. The apprenticeship programme is open to anyone, but is only funded for individuals aged between 16 and 24. The NVQ: The NVQ is designed for people who are able to carry out administrative functions as part of their daily role. The course includes:

• Giving customers a positive impression of the organisation

• Promoting additional services or products to customers • Processing customer service information • Going “the extra mile” in customer service • Providing good customer service within the rules • Living up to the customer service promise

Programme Information Continued

Functional Skills: GCSE’s are not, in the opinion of employers, giving individuals the necessary skills required in the work place. Functional Skills are transferable skills that are valued by employers and provide a base from which individuals can develop other employability skills. They are tools that enable people to:

Apply their knowledge and understanding in everyday life Engage competently and confidently with others Solve problems in both familiar and unfamiliar situations

Technical Certificate: This provides individuals with the underpinning knowledge required to carry out their role effectively. It contains information on health & safety and legislation. Knowledge is confirmed through completion of an on line assessment. Employment Rights & Responsibilities: This provides individuals with information about their organisation, such as, contracts of employment, policies and procedures, equality & diversity, data protection and general sources of information and advice. Assessment & Delivery: Assessment is conducted by a qualified assessor, with a wealth of experience and occupational competency in the area of learning. There are many ways that an individual’s competency can be assessed and these include:

Observation Product Evidence (naturally occurring in the workplace) Questioning Guided Discussion

All assessments take place on the job, it is anticipated that a small amount of down time will be required to complete the functional skills element of the framework.


Business & Administration Apprenticeship

Framework:

9 month programme

NVQ L2 in Business & Administration

Functional Skills in Maths & English

Award in Administration


Costs:



NVQ L2 in Business & Administration Functional Skills in Maths & English Award in Administration Employment Rights & Responsibilities

It is a 9 month programme and all elements must be completed in order to achieve an apprenticeship in Business & Administration. The apprenticeship programme is open to anyone, but is only funded for individuals aged between 16 and 24. The NVQ: The NVQ is designed for people who are able to carry out administrative functions as part of their daily role. The course includes:

• Maintaining a safe working environment • Working towards the organisations objectives • Managing customer relations • Using IT in administration • Researching and reporting information • Working effectively with other people


ITQ Apprenticeship

Framework:

9 month programme

NVQ L2 in ITQ



Costs:


The Apprenticeship Framework: The framework is made up of three elements:

NVQ L2 in Information Technology Qualification Functional Skills in Maths & English Employment Rights & Responsibilities

It is a 9 month programme and all elements must be completed in order to achieve an apprenticeship in Information TechnologyQualification. The apprenticeship programme is open to anyone, but is only funded for individuals aged between 16 and 24. The NVQ: The NVQ is designed for people who are working in a manufacturing environment and this can apply to a variety of disciplines. The course includes:

• IT troubleshooting • IT maintenance • Specialist and bespoke software • Using IT to exchange information • E mail • Spreadsheets


Performing Manufacturing Operations Apprenticeship

Framework:

9 month programme

NVQ L2 in Performing Manufacturing Operations


Certificate in Manufacturing Practices


Costs:



NVQ L2 in Performing Manufacturing Operations Functional Skills in Maths & English Certificate in Manufacturing Practises Employment Rights & Responsibilities

It is a 9 month programme and all elements must be completed in order to achieve an apprenticeship in Performing Manufacturing Operations. The apprenticeship programme is open to anyone, but is only funded for individuals aged between 16 and 24. The NVQ: The NVQ is designed for people who are working in a manufacturing environment and this can apply to a variety of disciplines. The course includes:

• Health, safety and security in the workplace • Storage, • Transferring materials • Preparing for manufacturing operations • Complying with statutory regulations and organisational

safety requirements • Analysing the results if inspection and confirming quality

of production

Activity Plan

Performing Manufacturing Operations Apprenticeship

Week No. Activity Time Required

1 Induction & Initial Assessment 1 day - off the job

3 Skills Gap Assessment/ERR 1 day - off the job

5 Functional Skills /ERR 1 day - off the job

7 Functional Skills/Technical Certificate 1 day - off the job








23 Observation of Work Practice ½ day – on job assessment



29 Professional Discussion ½ day – on job assessment

30 Portfolio Sign Off ½ day – on job assessment

32 Key Skills Assessments 1 day - off the job

34 Technical Certificate Assessment 1 day - off the job


Performing Engineering Operations Apprenticeship

Framework:

12 month programme

NVQ L2 in Performing Engineering Operations

Functional Skills in Maths, English & ICT

Technical Certificate appropriate to chosen pathway


Costs:



NVQ L2 in Performing Engineering Operations Functional Skills in Maths, English & ICT Technical Certificate Employment Rights & Responsibilities

It is a 12 month programme and all elements must be completed in order to achieve an apprenticeship in Performing Engineering Operations. The apprenticeship programme is open to anyone, but is only funded for individuals aged between 16 and 24. The NVQ: The NVQ is designed for people working on engineering related tasks as part of their daily role. The course includes:

• Working safely in an engineering environment • Working efficiently and effectively in an engineering

environment • Using and communicating technical information • Making components using hand tools and fitting

techniques] The above list is only a small sample of the units available and the qualification can be tailored to the operator’s job role.






All assessments take place on the job, it is anticipated that some down time will be required to complete the functional skills element of the framework.


Warehousing & Storage Apprenticeship

Framework:

9 month programme

NVQ L2 in Warehousing & Storage


Certificate in Warehousing & Storage Principles


Costs:



NVQ L2 in Warehousing & Storage Functional Skills in Maths & English Certificate in Warehousing & Storage Principles Employment Rights & Responsibilities

It is a 9 month programme and all elements must be completed in order to achieve an apprenticeship in Warehousing & Storage. The apprenticeship programme is open to anyone, but is only funded for individuals aged between 16 and 24. The NVQ: The NVQ is designed for people who are involved in either the movement of goods, hygiene, customer service and stock control or a combination of these within a warehouse environment. The course includes:

Health, safety and security in the workplace Storage Processing orders Receiving deliveries Assembling orders for dispatch Dispatching orders Working effectively within the organisation




Technical Certificate: This provides individuals with the underpinning knowledge required to carry out their role effectively. It contains information on health & safety and legislation. Knowledge is confirmed through completion of an on line assessment. Employment Rights & Responsibilities: This provides individuals with information about their organisation, such as contracts of employment, policies and procedures, equality & diversity, data protection and general sources of information and advice. Assessment & Delivery: Assessment is conducted by a qualified assessor, with a wealth of experience and occupational competency in the area of learning. There are many ways that an individual’s competency can be assessed and these include:



RAPID

IMPROVEMENT WORKSHOPS

5s & Workplace Organisation 1 day

The quality of your working environment can have a big impacton the e�ciency of your operations. A well organised workplacewith an e�cient layout saves time, reduces accidents, increasesproductivity and improves quality.

What is 5s?5s is often referred to as housekeeping, however the elements of 5s, and of this workshop, go beyond that. 5s is a philosophy that,when adopted within an organisation, can signi�catnly improve the e�ciency of the organisations activity.

Workshop Content

Unlike most other 5s programmes this 1 day workshop is made up of 20% theory and 80% application so actual improvements are made to your workplace.

The theory covered includes:Origins of 5s Elements of 5sRed Tagging5s Audit SheetsSustaining the e�ort

A Business Impact Consultant will work with you to identify areasfor improvement within your organisation to ensure that you receivethe best possible bene�ts from the workshop.

Rapid Improvement Workshops

• Tangible improvements within your workplace

• Improved sta� skill levels

• Increased product and process quality

• Immediate results

• Improved health and safety • Decreased down time


Kaizen & Continuous Improvement 1 day

Adopting and implementing a Kaizen philosophy is key to ensuringyour business processes are continuously improved to drive down costsand increase competitiveness through improvements in quality, time spenton activities.

The key to adopting this philosophy and ensuring it is as successful as possible within your organisation is not only ensuring your sta� have an understanding but are also able to implement it within the workplace.

This one day workshop covers both of these elements by developing the knowledge of your sta� and facilitating an improvement project in your workplace with the group taking part.

Workshop Content

Unlike most other Kaizen programmes this 1 day workshop is made up of 20% theory and 80% application so actual improvements are made to your workplace.

The theory covered includes:Kaizen de�nition and teamworkThe PDCA cycleCheck sheets and Pareto analysisThe seven wastesIdentifying waste in a process Reducing waste in A process



• Reduced waste • Improved sta� skill levels

• Cost savings • Immediate results

• Helps create a culture of continuous improvement


FMEA (Failure Mode and E�ects Analysis) 1 day

The ability to improve your business processes is key to ensuring youroragnisation drives down costs, improves quality and boosts productivity. Having people within your organisation with the skills to be able to identify valuable areas for improvement goes a long way to achieving this.

What is FMEA?Failure Mode and E�ects Analysis is a tool used to identify potentialfailure modes within a process, determine their e�ect on the quality of the process and its outcome and identify corrective meauresto combat those failures which cause the greatest potential risk.

Workshop Content

Unlike most other FMEA programmes this 1 day workshop is made up of 20% theory and 80% application so actual analysis is carried out in your workplace.

The theory covered includes:The concept of FMEA and riskDesign FMEA and process FMEACalculating RPN - Severity, Occurence, DetectionThe FMEA sheetCreating an action plan using FMEA



• Improved quality

• Improved customer satisfaction

• Reduced down time

• Creates emphasis on problem prevention

• Reduced waste • Improved sta� skill levels


Introduction to Lean Manufacturing 1-day programmeThe Lean concept is basically all about getting the right things, to the right place, at the right time, in the right quantity while minimising time, in the right quantity while minimising waste and being open to change - and it applies to the whole of the organisation from order entry to accounts received. It demands effective leadership, commitment and engagement of the workforce to create a flexible and responsive organisation. This session introduces the fundamental concepts and philosophy of Lean methodology and allows participants to apply these in a simple ‘production line’ practical activity.


Key Outcomes:

Upon successful completion of this module the participant will be able to: 1. Describe the principles of Lean Manufacturing and the benefits of applying lean concepts across a business.

2. Explain the importance of Standard Operating Procedures

3. List the stages in the application of a 5s programme

4. Define the terms value-add and non value-add in a Lean Manufacturing environment.


Introduction to Lean Manufacturing 2-day programmeThis 2-day programme provides participants with a practical introduction to the topic of Lean Manufacturing and also introduces some of the essential tools required to categorise, monitor and control processes. Through a combination of classroom sessions, practical activities and workplace audits, participants experience first-hand the tools, techniques and methodologies that today’s manufacturing companies use to reduce costs and increase productivity.



Key Outcomes:

Upon successful completion of this module the participant will be able to: 1. Describe the role of value, flow, pull and waste reduction in a Lean Manufacturing environment

2. Explain the importance of standardisation

3. List the eight Lean KPI’s

4. Explain the use of Takt time to match output to customer demand

5. Calculate basic capability indices (Cp/Cpk)

6. Describe the link between variation and the Normal distribution

7. Explain the fundamentals of Statistical Process Control

8. Select appropriate methods to arrange and organise ideas as part of the problem solving process

Introduction to Lean Manufacturing 5-day programmeApplication The Practical Introduction to Lean Manufacturing module is designed to provide an understanding of the principles of Lean Manufacturing and how these principles can be applied within the workplace. This programme introduces the fundamental concepts and philosophy of Lean methodology and allows participants to combine these with the essential support tools and techniques to ensure effective application.


Key Outcomes:

Upon successful completion of this module the participant will be able to: 1. Describe the principles of lean manufacturing and the benefits of applying lean concepts across a business.

2. Understand production smoothing, SMED and how this enables JIT flexibility.

3. Explain the terms, Flow, Pull, Takt, JIT and Jidoka and how these relate to the strategic implementation of lean manufacturing.

4. Recognise the key elements and fundamentals of lean manufacturing including identification and elimination of waste, visual management, workplace organisation and standardisation.

5. Demonstrate the use of Value Stream Mapping to identify value added and non-value added activity.

6. Collect and analyse live data from a process (selecting the correct problem solving tool) using Quality, Cost and Delivery criteria.

7. Apply the principles of cellular working and workplace organisation (e.g. 5S and Visual Management Systems) to improve the effectiveness, flexibility, response, quality and safety of the work area.

8. Identify, categorise (using the seven wastes model) and prioritise waste from a process.

9. Develop standardised work plans to eliminate variation from the process.

10. Apply effective visual management to sustain improvements within the workplace.

11. Apply tools and techniques to reorganise and evaluate a process using Lean criteria.

12. Demonstrate an understanding of the application of Lean principles and communicate this to others.


The Lean Leader Programme (Level 3)The Lean Leader is a programme of knowledge and skills based on an Institute of Leadership & Management qualification that has been enhanced to address the effective implementation and sustainability of Lean projects in either Manufacturing or Service environments.

The aim of this programme is to provide tailored leadership and management skills to Supervisors, Team Leaders, Managers and Change Agents to maximise the sustainability of Lean initiatives and business improvement programmes in both Manufacturing and Service organisations. The course will provide candidates with appropriate Lean Leader skills and knowledge, support them to apply these to live Lean initiatives and business improvement programmes, and enable them to measure business improvements.



Objectives:

• Providecandidateswithappropriate Lean Leader skills and knowledge

• Supportthemtoapplytheir knowledge and skills to a live initiative or Business Improvement programme

• Enablecandidatestomeasure business improvements, with specific focus on Quality, Cost and Delivery.

Management to LeadershipThis programme is designed to provide the essential skills that today’s managers require to implement and drive productivity improvements within the organisation by becoming effective leaders.

The programme consists of three topic areas:

• How to lead and be effective• Utilisation of selected productivity tools and techniques• Strategies for making change happen

Each participant will understand what they have to do to improve their leadership skills and they will be helped to make the necessary adjustments as they learn how to use selected productivity tools and techniques to improve the performance of a process.

This programme is unique in achieving immediate improvements in how the participant impacts their team, colleagues and customers - while identifying and eliminating waste and inefficiency in the manufacturing process. The programme consists of three modules:

1. Leadership for managers2. Selected productivity tools and techniques3. Strategies for change and project management



CASE STUDIES / TESTIMONIALS

Current clients that we work with........

Case Study – Arla Foods, Palmers Green

We have been working with Arla Foods at their Oakthorpe Site since May 2009 and so far 30 learners have completed their BIT Level 2. Arla have been extremely pleased with our progress and the changes he has seen take place onsite since we started last year. Our contact at Arla foods; the Continuous Improvement Co-ordinator believes these changes have been a direct result of the programmes we have delivered there. He has also been fully involved in the programme and is currently working towards his Level 3 having completed Level 2. He said the most valuable factor to come out of the training has been to see the learners engage and start to utilise their new skills after the NVQs have been completed. This has also been a great help to the company as learners are starting to be set their personal development plans and continuous improvement is an objective everyone is being set. A key improvement that has been made was to put a procedure in place to ensure a piece of equipment (Cyroscope) no longer needed to be calibrated and parts replaced every month. This simple improvement has saved Arla over £700 per month since July 2009; £6,300 so far. Since this projected was completed in the laboratory, all equipments that are used now have similar care points introduced and the Cyroscope has not needed to be serviced since July 2009. In the Cream Department, one of the issues raised was around time being wasted when labels ran out on the labelling machine. The team looked at different ways of solving this and came up with an effective use of visual aids and hourly checks to ensure the labels never ran out. They then attached a Perspex top to the labeller and when the reel goes into the “red”, the operator, who has to carry out hourly checks replaces the reel and ensures the line continues to run. This has saved over 2 hours per day of “downtime” that was caused by labels running out. The improvement teams also looked at organising labels in the milk filling plant and organising the engineering materials. This has saved them time when looking for parts and also ensures that the labels are kept in the correct condition. Due to these small improvements Arla have also passed inspections by Tesco, Co-op and Sainsburys.

Case Study – Rolls Royce, Barnoldswick

Thirty six learners formed the first four pilot groups over two sites at Rolls Royce in Barnoldswick near Burnley. These two sites manufacture all the turbine blades for Rolls Royce engines worldwide. The first pilot groups have completed and we are currently enrolling new learners across all sites. The main challenge for us was to align the Business Improvement Techniques Level 2 qualification against the Rolls Royce “Process Excellence” journey. The first pilot group was a mixture of learners; two young apprentices, a doctor, a black belt, a green belt and the remainder were engineers. Our biggest challenge with that group was to create differentiation between the learners. They were part of the transactional team that led them to complete the projects around “Process Flow” within the internal FPA system. The FPA system is an internal vehicle with which to authorise change to processes. They successfully reduced NRFT of the FPA passing at the review board by changing flow process by creating an SOP to control this. The team created an internal programme to monitor the FPA’s. After that they looked at how the “Management of Change” (MOC) documentation was affected by the FPA and how it impacted on lead time. The final project was around parts awaiting sign off allowing them to go to stores to be sold. All projects that were implemented were successful and action plans are in place for the team to move forward. Another pilot group comprised of shop floor operatives and engineers and they looked at “blade rework reductions” at the Bankside site and also “improving die-set turnaround” at the Ghyll Brow site. Initial improvement figures for both groups are extremely encouraging and again action plans are in place to carry this forward. Rolls Royce is currently enrolling groups across other sites.

Selex Ltd Testimonials

Being in a supervisory role, the Lean Manufacturing training program has provided me with a sound basis for the promotion and implementation of successful process improvement ideas. This in turn leads to the encouragement of all staff members to become involved in further improvements that they know will achieve results.

Andy Gardner Production Test Manager UK Operations SELEX Communications Ltd has been using the Business Improvement Techniques NVQ course as a key element of our training strategy for our Operations staff. The course dovetails very effectively with our lean manufacturing strategy. So far 16 of our people have achieved NVQ level 2 and this year we plan to put 13 through level 3 training as well as running another level 2 course. The course has been very popular with the trainees who have enjoyed the mix of theory and practical hands-on projects many of which have provided sustained process improvements for our business. In addition, the methodology advocated by the trainers has become the basis for our own in-house lean improvement team, formed from the course graduates. Business Impact’s trainers are both knowledgeable and professional, and I would have no hesitation in recommending this training scheme. Andy Forrester Efficiency Improvement Manager UK Operations

Camerons Brewery Hartlepool Testimonial

As the brewing industry consolidates within the UK through brewery closures due to the economic downturn, we have set our stall out to be a contact brewer of major brands. To be successful within this very competitive arena, we have to be capable of demonstrating to our prospective and existing clients that we will take the utmost care in producing their valuable brands to their exact expectations. To meet this need we have invested more than £4 million in the brewery infrastructure however it does not end there. Camerons’ recognise that the development of its staff is crucial to ensure that industry best practice is adopted within the brewery. Through involving Business Impact as our main training provider, we have embarked on a fundamental organisational development programme that encapsulates the Lean Manufacturing ethos. So far 50 employees have gained an NVQ level 2 in Business Improvement Techniques that has been delivered by Business Impact through a suite of classroom workshops and workplace applications. I’ve been impressed by the standard of tuition and expertise in nurturing students along, many of which have not studied in many years. The next phase of the training programme has commenced with the remaining 50 employees being involved. We have suggested a level 3 course as a follow up and have been inundated with volunteers. Well so far what has the course delivered? That of course is best answered by our customers! Comments from a customer visit last week: The improved work standards and communications are also a sign that you are openly working to a more organised and structured approach. The use of displays for the Lean audits as well as the work instructions show that these are actively in use with the teams - and are not just something being discussed in the offices. It really has been good to track the changes over the last year, but the visual impact of the tour yesterday really helped enforce the higher standards being implemented. Billy McKee Commercial Director Cameron's Brewery

Guardian Print Centre Manchester Testimonial

Guardian Print Centre (Manchester) has employed Business Impact to implement the NVQ in Business Improvement Techniques (Level 2). The programme is currently being delivered to all employees throughout the organisation. Benefits and improvements have already been realised on a cost, quality and delivery platform. Attendees have taken part from all departments with the emphasis on encouraging cross functional team development. The course mixes under pinning knowledge sessions with real improvement projects so as to create a shop floor culture of continuous development and improvement. I can highly recommend Business Impact as a provider of the NVQ programme. As a training provider, they understand the problems experienced in rolling out such a programme in a highly skilled manufacturing process environment. They have been flexible in arranging courses to suit production and also adapting the course to suit the organisation's requirements. The two trainers used have both been friendly, approachable, knowledgeable and professional with excellent feedback received from those who have already passed the course. GPC Manchester is looking forward to continuing it's partnership with Business Impact as a training provider. Ade Knott Line Manager Guardian Print Centre

General Mills, Berwick upon Tweed Testimonials

“Business Impact staff were useful as a resource, seeing the factory floor with fresh eyes. Their broad awareness of manufacturing processes and standards has helped us immensely” “Business Impact staff were professional, friendly and helpful. They easily established a rapport with your workforce, integrating in the business and interacting with our staff very well” “After company induction for Business Impact staff, very little input was needed from us” “Business Impact staff carried out training with minimal disruption to production and always gave a clear update on progress” They brought their own paperwork, files etc. so no additional administration was needed. Working out of the small area, couple of desks, chairs and some storage space was all they needed. Sometimes we forgot they were Business Impact staff and not our own!” “The trainers were flexible in terms of providing BIT overview sessions for Area Managers and meeting with Hygiene Manager to design new training for next year. They were always prepared to offer support and share their learning’s with the business” Fiona McIntosh, HR Manager Brian Douglas, Production Manager General Mills

For further details on how we may assist you further please contact us directly on 0191 4971920. Business Impact UK Ltd (Head Office) Endurance House Colmet Court Seventh Avenue Team Valley Gateshead NE11 0EF [email protected] www.businessimpactuk.com

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http://www.businessimpactuk.com/

Skills Portfolio 2010

Documents

Transcript of Skills Portfolio 2010