Lean

Lean Leadership

Location of Course TBA
Trainer Professor Peter Hines
For more than 20 years, Peter Hines has been advising business leaders on how to embed ‘lean systems thinking’ in order to transform business performance. Peter is a co-founder of the Lean Enterprise Research Centre at Cardiff Business School, the largest dedicated research centre in Lean Thinking in the world, and a prize winning author.
Further Enquiries Michelle Reinecke-Quain
Life Sciences Skillnet Administrator
Email: michelle.reinecke-quain@ibec.ie
Phone: 061 431802
Course Content Overview of Lean Thinking:
• Lean Principles
• Lean Iceberg Model
• Lean Business Model and Lean Maturity Assessment:
• Strategy Deployment
• Value Stream Management
• Tools and Techniques
• People Enabled Processes
• Extended Enterprise

• Case Studies
• Creating Your Roadmap
• Next Steps and Action Planning

Workshop Objectives
• Understand how Lean Thinking provides the basis for a profitable, growing and customer-focused business
• Identify where your organisation is on its Lean journey
• Create a 3-year vision for your business from a Lean perspective
• Identify the priority actions to achieve this vision and start developing a roadmap to get you there
• Understand the role of the senior team in creating a Lean enterprise.

Enrolment and Start Dates Comment September - November 2013
Network Manager Pauline O'Flanagan, pauline@lifesciencesskillnet.ie
Subjects Taught Lean Leadership
Duration 8 days
Number of Places Open
Course Fee Life Sciences Skillnet Members: €1,750 per life sciences member
Available to Job Seekers: 
Yes
Certified: 
No

Lean Manufacturing Tools

Location of Course Carlow Gateway Business Centre, Athy Road, Carlow
Trainer Ray McEvoy, Manufacturing Excellence
Methods of Assessment For the purposes of FETAC Accreditation, candidates will complete the following three assessments:

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.

Learning Outcomes Learners who successfully complete this module will be able to:
• Conduct Lean improvement activities in their own area of responsibility, such as 5S, Kanban, SMED, Standard Work and Mistake Proofing and
• Assist senior management in implementing Lean Principles in a wider manufacturing environment
Further Enquiries Theresa
t: 059 913 2152
e: admin@cktraining.ie
Course Content Learning objective:
A Lean Enterprise delivers maximum value to its customers using the minimum amount of materials, labour, finance and other resources.
Financial Support (Free to Job Seekers on a first come basis)
Click link below for eligibility
www.skillnets.ie/job-seekers/eligibility-criteria.
Enrolment and Start Dates Comment Enrolment is ongoing.
Delivery dates are as follows:
8th, 15th, 22nd, 29th of May and 5th of June, 2013
Subjects Taught Day 1 - Lean Overview.
Lean Simulation game
Project & Metrics selection

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

Duration Five days ran over one day a week for five weeks.
Comment Note: Plant visits and exercises will be coordinated by R. McEvoy through SELF (South East Lean Forum)and / or the participants own plants. The VSM & SMED exercises will be conducted at a participant’s plant.
Course Fee €325 per person
Available to Job Seekers: 
Yes
Certified: 
No

Lean Six Sigma (Green Belt)

Network: 
Biznetcork Skillnet
Location of Course River Lee Hotel & Radisson Blu Hotel, Cork
Trainer David Campbell - Alora Consultants
Methods of Assessment The trainees will be evaluated on 2 different levels.

Level 1 – Reaction
The reaction of the trainees to the training programme will be evaluated at the end of each day through an informal feedback method and at the end of training programme through a formal feedback form. The results of the feedback will be shared with the Client.

Level 2 – Learning
The skills, knowledge and attitude of the trainees will be evaluated at the end of the programme by the completion of an examination. Results will be shared with the attendees and the Client.

Learning Outcomes By the end of this training programme the attendees will be able to:
1. Understand Continuous Improvement.
2. Understand Lean Six Sigma methodology and DMAIC.
3. Understand Change Management and tools used.
4. Understand how to use the most important tools in DMAIC phases.
5. Identify sources of waste and variation within the business.
6. Use Lean Six Sigma as an efficient and effective cost reduction strategy.
Eligibility This course is intended for those employees within a business who are engaged in daily problem solving and / or project management, for example Process Engineers, Quality Technicians and Engineers, Maintenance, Supervisors, Managers and Project Managers.
Further Enquiries Aoife Dunne
Training Administrator
t: 021 453 0141
e: aoife@corkchamber.ie
Course Content Continuous Improvement (CI) has been part of business practice for decades. Essentially CI is a ‘change for the better’. Sometimes we perform these changes as part of our day-to-day business activities, other times we need to have a specific goal or objective to achieve that takes the form of a project.

Lean Six Sigma Green Belts are vital assets to any business. They are key employees equipped with specialist tools to make these ‘changes for the better’ happen. Utilising a vast array of tools, Lean Six Sigma focuses on improving speed and quality of a product or service, regardless of the industrial sector or size of the business, helping a business in becoming better and faster, providing a greater value product to the customer.

Lean Six Sigma Green Belts are extremely flexible weapons in reducing costs. They can lead cost reduction projects, simply be project team members or use Lean Six Sigma tools whilst performing key everyday activities. Green Belts help a business in becoming better and faster. Green Belts impact the bottom line.

Green Belt Training includes Lean, Six Sigma and Change Management tools and methodologies. The training focuses on utilising the most common Lean Six Sigma and Change Management tools in the execution of medium complexity projects. The format of the training will be tutor led. The training is very interactive thus there is a lot of emphasis on group dynamics and ensuring the attendees participate and interact with the trainer and each other. The training is conducted through presentations, simulations, role plays, group exercises,
discussions and case studies.

Enrolment and Start Dates Comment 8 Days:
Day 1 & 2:
4th & 5th April 2013 - River Lee Hotel, Western Road, Cork

Day 3 & 4:
25th & 26th April 2013 - River Lee Hotel, Western Road, Cork

Days 5 & 6:
9th & 10th May 2013- Radisson Blu Hotel, Little Island, Cork

Day 7:
24th May 2013 - River Lee Hotel, Western Road, Cork

Day 8:
7th June 2013 - River Lee Hotel, Western Road, Cork

Duration 8 days
Course Fee Chamber Member Rate: €900.00
Chamber Non-Member Rate: €1,170.00
Available to Job Seekers: 
Yes
Certified: 
No

Manufacturing Business

Location of Course Waterford Institute of Technology
Trainer Waterford Institute of Technology
Methods of Assessment Online Assessment - Facilited in the Workplace or College
Learning Outcomes 1. Students will learn to understand why we use Risk Assessments and how to write one.
2. Understand why SOP's and policies are in place which greatly increases the liklihood of compliance.
3. Problem solve on a day to day basis; apply methodolgies such as root cause analysis.
4. Gain an understanding of the elements of Project Management which increases the success rate of immiment projects.
Further Enquiries Conact Sara - 051 311139
Email: skillnet@waterfordchamber.ie
Entry Requirements Fetac Level 5 or relevant life experience
Careers or Further Progression The minor award is offered part time over 6 months. The certificate is promotes on the job learning combined with online delivery amd assessment of up-to-date and approved content. The result is a nationally recognised qualification which provides a further step onto the National Qualifications Framework and cane be used to set in motion staff progression through certificed training.
Course Content The Certificate is aimed primarily at operations and supervisory staff in the manufacturing plant. It is devised to suit a variety of industries including Pharma, medical devices, high volume manufacturing and food based manufacturing.
The user friendly content delivery enables employers to manage shift cycles and upskill staff with far greater results.
Financial Support Funding applied
Enrolment and Start Dates Comment Enrollment Date: 22/05/2013
Start Date:30/05/2013
Subjects Taught The topics covered:
1. Manufacturing Systems and Standards
2. Lean Manufacting
3. Health & Safety
4. Quality Manufacturing
5. Project Management
Duration 6 months - Each Thursday afternoon from 2:00 - 5:00pm
Time allowed for holidays during August
Comment Successful participants of this programme shall receive a HETAC Level 6 Minor Award and 40 credits on the NFQ.
Number of Places Available
Course Fee €650 per participant
Available to Job Seekers: 
Yes
Certified: 
Yes

Lean Manufacturing Tools

Location of Course Waterford Health Park, Slievekeale Road, Waterford & Carlow Town(venue to be confirmed)
Trainer Ray McEvoy, Manufacturing Excellence
Methods of Assessment The Six Sigma GreenBelt Certification is made up of two elements:
1. 3 hour, 80 Multiple Choice Questionnaire exam (open book).
2. Completion and presentation of an in-house project.

Note: Although this certification process follows a similar format to that used by the American Society for Quality (ASQ), the certification is not accredited by anyone other than Raymond McEvoy of Manufacturing Excellence. It would be considered a HETAC Level 6 course.

Learning Outcomes As well as completing the training modules, candidates will complete an in-house project,typically as part of a small cross-functional team. Projects that deliver savings of about €25,000 per annum would normally be considered appropriate Greenbelt projects.
Further Enquiries Sara - 051 311139
Email - skillnet@waterfordchamber.ie
Entry Requirements This program is suitable for managers, engineers and technicians.
Careers or Further Progression Six Sigma Black Belt
Course Content This program equips the candidate to identify the waste in the existing operation, propose a viable Future State and use many of the tools such as Value Stream Mapping, Kanban, Load-Cycle charts and Kaizen workshops to achieve significant operational improvements.
Financial Support Funding applied
Enrolment and Start Dates Comment Enrollment Dates: 7th May 2013
Start Date: 8th May 2013

Dates: 8th, 15th, 22nd, 29th May, & 5th June 2013

Subjects Taught 1.Value Stream Mapping
2.Identifying Waste
3.Material Flow
4.5S Workplace Organisation
5.Standard Work and Load Cycle-time Charts
6.Layout
7.Teamworking and Chartering
8.Improvement Cycling
Duration 5 days with additional study.
Number of Places Available
Course Fee Skillnet Member €325
Chamber Member: €375
Non Member: €400
Available to Job Seekers: 
No
Certified: 
No

Toyota A3 Problem Solving Methodology

Location of Course First Polymer Training Skillnet
Methods of Assessment Module Description:
A3 Problem solving is a Lean tool which promotes consensus based problem solving, utilising a systematic, documented methodology. It is also a communication tool that follows a logical and standard structure. It’s use is becoming widespread among many industries and it is an extremely versatile tool which can be easily trained to an entire organisation in order to enable standard responses to problem solving.

Module Content:
• Introduction and over view of the 5 principles of Lean thinking
• Introduction to the concept of A3 Problem solving methodology and benefits of using the methodology
• Creating an A3, how to effectively establish the program
• A3 used as a communication tool for a company

Who should attend:
Attendees at this module should be persons engaged and leading the Lean transformation program, and also Engineers, Technicians and Operators who work in the company.

Learning Outcomes Learning Objective:
Participants on this module will gain a clear understanding of the principles and workings of the A3 solving model. They will clearly understand how to effectively deploy the methodology and use the tool to engage a group on resolving complex problems.
Further Enquiries Tel 090 6471223
Fax 090 6471221
Email: info@firstpolymer.com
Duration 1 Day
Course Fee €395. Inclusive of course manual, lunch and refreshments.
Available to Job Seekers: 
Yes
Certified: 
No

Value Stream Mapping

Location of Course First Polymer Training Skillnet
Further Enquiries Tel 090 6471223
Fax 090 6471221
Email: info@firstpolymer.com
Course Content Value Stream Mapping
Value Stream Mapping is a systems approach to Lean Manufacturing, based on looking at the complete flow of a selected control part through its sequence of operations. The purpose of a value stream map is to identify waste, particularly excess inventory, in the process and then to develop an improvement plan to reduce that waste. A complete Value Stream Mapping project consists of a Current State Map - where we are now, a Future State Map - the ideal, and an improvement plan to move from the current state towards the ideal future state. At the same time as mapping material flows, an important part of the Value Stream Mapping process is to map information flows, and we can help you select a pacemaker process and synchronise information and material flows.

Workshop Programme
» Introduction and getting started
» Select product families for the practical exercises
» The current state map
» Classroom exercise 1: (class) Create a current state map
» Practical exercise 1: (shop floor) - teams create current state maps
» What is a Lean Value Stream?
» The future state map
» Classroom exercise 2: use case study to create a future state
» Practical exercise 2: following roadmap, teams create future state maps of their Value Stream
» Review future state
» Achieving the future state
» Develop a formal implementation plan
» Create specific / detailed kaizens
» Formalize and present out to senior management for plan acceptance
» Workshop conclusion

Participants Will Learn To: Plan and link Lean initiatives to avoid the pitfall of "cherry picking" lean tools in a series of haphazard kaizen events Use a "storyboard" to succinctly display and communicate the current and future state maps, key metrics, and a summary of the mapping process Create a prioritised implementation plan of which Lean tools to use and where to use them for optimal payback Properly apply such key Lean tools and techniques as takt time, buffer and safety stock calculations, continuous flow cells, operator balance charts, standard work, regulating pull systems with kanban, pitch and heijunka, the proper role for MRPII, and OEE and value added ratios.

This course will take you through a step-by-step method of value stream mapping and storyboarding. You will understand how to gather the information needed to eliminate all non-value adding waste, and how to use it to plan the implementation of your Lean activities You will create a visual Value Stream Management Map from supplier to customer through all the internal production processes for one or more product lines. You will learn how to optimize both material and information flow by actually applying Value Stream Management to eliminate the root cause of waste. Simulated practice followed by application of the tool to actual products lets you apply the knowledge and promotes immediate results during the event. This technique also teaches a satisfying team approach to continuous improvement.

What you will learn
At the completion of the workshop, the participants will have created a current state map and developed their own future state map. As well as taking participants through the process of developing Current State and Future State Maps, using a video case study exercise of a white goods factory, the workshop details the fundamental tools used to develop flow on the shopfloor. Workshop participants will work in teams to practice these tools in case study exercises, and develop a project plan for their first Value Stream Mapping project in the workplace

Who should attend
Production and Managers and Engineers. Supervisors and Team Leaders. Continuous Improvement and Quality Control Facilitators.

Duration 1 Day
Course Fee €395
Available to Job Seekers: 
Yes
Certified: 
No

TPM- Total Productive Maintenance

Location of Course First Polymer Training Skillnet
Learning Outcomes What you will learn
How TPM differs from other Maintenance Practices
The Importance of Measurement in TPM
How TPM Programmes are Structured
How to adapt TPM to your own company
How TPM uses the PDCA Cycle and Kaizen
How TPM Affects the Design and Procurement of Equipment
The Key Factors to Successful TPM Implementation
How to Set a Realistic Timetable and Accurately Measure Results
Further Enquiries Tel 090 6471223
Fax 090 6471221
Email: info@firstpolymer.com
Course Content A practical two-day training workshop on implementing Total Productive Maintenance. This programme can also be delivered over one day, depending on the customers requirements.

Total Productive Maintenance - TPM
TPM is a dynamic team-based methodology for involving all employees in developing a long-term preventive maintenance programme and for reducing unscheduled stoppages, breakdowns, instability and unreliability. Maintenance people concentrate on preventive measures, maintenance analysis, designing machines for maintainability, and educating the workforce.

Operators become full partners with Maintenance and assume responsibility for ensuring that daily tasks (data gathering, cleaning, lubricating, checking, etc.) are performed.

TPM combines the practice of preventive maintenance with Total Quality Control and Total Employee Involvement. It is a deceptively simple yet decidedly revolutionary system of on-going maintenance that is transforming the face of modern manufacturing.

TPM relies on small-group activities and participative input, total employee involvement and dedication to quality of equipment care. TPM teaches us how to prevent breakdowns, so critical in any manufacturing company seeking world class performance.

Workshop Programme
Definition and Aims of TPM
TPM Results and Benefits
TPM, TQC and Traditional Maintenance
Developing TPM Activities
Maximising Overall Equipment Effectiveness
Understanding Equipment
Management Policy, Goals and Targets for the TPM
Teams Loss
Structure, Equipment Efficiency and Analysis
Calculating Overall Equipment Effectiveness
Visual Information and Activity Boards
Getting Organised through the 5S's
Equipment Loss Analysis and Data Gathering
Autonomous Maintenance and Problem Solving
Equipment Training and One Point Lessons
Autonomous Maintenance, Kaizen and Teamwork Maintenance
Prevention and Quality Maintenance
Structures for Implementation

Who should attend
Production, Engineering and Maintenance Managers, Engineers, Fitters and Technicians

Duration 2 Days. A practical two-day training workshop on implementing Total Productive Maintenance. This programme can also be delivered over one day, depending on the customers requirements.
Course Fee €795
Available to Job Seekers: 
Yes
Certified: 
No

SPC- Statistical Process Control

Location of Course First Polymer Training Skillnet
Trainer TBA
Further Enquiries Tel 090 6471223
Fax 090 6471221
Email: info@firstpolymer.com
Course Content Overview
The cost of quality is the expense of not doing things right first time, causing valuable resources to be spent finding and reworking defective products.

Statistical Process Control (SPC) eliminates this waste acting as a detection device to indicate when something is going wrong with the process. Superior Product Quality is achieved by identifying and resolving the causes of the process variation. SPC is an essential tool for companies implementing ISO 9000, QS 9000 and Six Sigma.

Course Content
Why SPC? (Understanding process variation in plastics processing) Descriptive statistics

How to select appropriate control charts
Getting SPC started - how to set up SPC charts
Interpreting SPC charts

Process Capability (Cpk) analysis

AQL- sampling techniques, acceptance plans, ISO, MIL, ASQ standards
Why conduct gauge studies
How to plan, conduct and analyse gauge studies

Estimating of % tolerance and %R&R
Variable and attribute gauges
Overcoming barriers to successful implementation
Using SPC to drive your process

Enrolment and Start Dates Comment 23rd & 24th May 2013
7th & 8th November 2013
Duration 2 Days, 9.15am – 5.00pm each day.
Course Fee €795 (10% discount for Plastic Ireland Members) Inclusive of course manual, lunch and refreshments.
Available to Job Seekers: 
Yes
Certified: 
No

Six Sigma- 5 day course

Location of Course First Polymer Training Skillnet
Trainer TBA
Learning Outcomes First Polymer Training & Cordatus Certification Standard The FPT course is a 5-day six sigma course aimed primarily at candidates from SMEs who employers do not have the budget/resources for a full scale internal six sigma programme. It also attracts candidates from larger firms who are scouting for their organisations in relation to adopting the six sigma approach to problem solving and who may be in the process of sourcing training providers. The course objective is to provide candidates with a grounding in project management, teamwork and six sigma techniques that will enable them to complete a DMAIC project successfully, and contribute a financial benefit to their organisation of >= €20K.

Learning Objective
At the end of this programme participants will be enabled to:
-Use a formal project management method, problem solving tools improve or eliminate process problems
-Lead a cross-functional team through successful project completion
-Quantify business and financial benefits for the organisation and the customer.
-Participants who complete a live project, that meets predetermined criteria, will be eligible to apply for Green Belt certification.

Further Enquiries Tel 090 6471223
Fax 090 6471221
Email: info@firstpolymer.com
Careers or Further Progression We offer workshop-based six sigma green belt training at First Polymer Training (FPT) in Athlone. Please see www.firstpolymer.com. It costs €1,795 per person. This price includes all course material, lunch each day and all refreshments. This 5 day course is certified by FPT & Cordatus.

Supplementary modules in Design Of Experiments and Statistical Process Control are also available through FPT, and completion of the SPC and DOE modules will prepare candidates for the public, internationally recognised, ASQ green belt examination (see http://www.asq.org/certification/six-sigma-green-belt/right-for-you.html).

Course Content Six Sigma Green Belt

Introduction
Six Sigma is an approach to continuous improvement that seeks to review and upgrade an organisation’s processes, in order to increase organisation profitability by providing increased customer value at a lower cost.
This approach combines programme management, project management, problem solving techniques and statistical analysis in the continuous review and revision of processes.

The 5-Day Green Belt programme is a certified programme for which participants will have to complete a project, show predetermined and quantified financial and business benefits, and pass a written multiple choice examination.

All workshops are interactive in nature and case-study based. The contents will be varied to cater for specific sectors represented at the training programme.
Participants seeking certification will be required to attend a post implementation review involving a presentation on the project a written examination and a certification ceremony.
Participants will be given assistance and support by the course facilitators, as required, during their project work.

Some features of our approach to learning are:
• The training is experiential i.e. "learning by doing", and each candidate works through a project during training

• The 5 day Green Belt training is blocked into 3-2 blocks, spaced to accommodate learning by doing

• Courses are delivered using extracts from the American Society for Quality curriculum (see www.asq.org ), and we use a combination of project work, validated savings/revenue and written examination to certify candidates

• We provide soft copies of all training materials to accommodate in-house training by the client at future dates

• We facilitate inter-company networks so you can learn from the experiences of other Six Sigma practitioners

• We provide supporting advice on Six Sigma introduction, programme development, change management, project and candidate selection as required by the client.

Preparation
Participants will be required to select a project on which to work during and post training. The participant’s organisation and the course facilitators will approve the project in advance.

Who Should Attend?
Middle management, supervisors and specialists (e.g. engineers, laboratory analysts, cost accountants). Knowledge of statistics is not required before attending the programme. The most successful participants are likely to be those who have supervisory experience, and who are well regarded as change agents within their workplace.

Duration 5 day course
Course Fee €1,795 - This is a 5 day course which includes soft copies of all training materials, a copy of the "Six Sigma Memory Jogger" pocket textbook and a folder, pad and pen for each attendee plus lunches and refreshments for the duration of the course.
Available to Job Seekers: 
Yes
Certified: 
No
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