Athlone

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.

• The concept of undertaking and discharging responsibility.

• Obtaining and retaining the support of people.

• Organisation, delegation and time management.

• Performance management, cost control, targets, goals and objectives.

• Monitoring performance, implementing corrective and preventive actions.

• Communication skills across the organisation structure.

• Effective communication skills with senior management, colleagues and subordinates.

• Understanding and applying the principles of motivation in a practical and effective manner.

• Recognising and rewarding good performance.

• Dealing with performance improvement issues.

• Planning and preparing for communications with employees relative to disciplinary or grievance issues.

• Dealing with difficult people.

• Problem solving skills.

Communications-
Communication skills are highly valued in the all aspects of our working and personal life.

Learners who successfully complete this module will:
• develop an awareness of the essential role played by communication in human interaction
• acquire communication skills relevant to vocational and personal development
• understand the communicative principles and practices involved in gathering and relaying information
• acquire the skills and confidence to convey and interpret meaning, in writing, orally and visually
• develop a critical awareness of communications messages and media
• explore the use of modern communication and information technology, and its application in personal and vocational life.

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.

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).

Day 1 –
• Descriptive statistics
• Graphing techniques to spot differences
• Identifying relationships using regression

Day 2 –
• t tests to see differences in means
• F tests to see differences in variation
• Proportion tests to see if proportions differ
• Confidence intervals and how they impact sample size

Course Details
The course will teach how statistics can be used to spot differences in data and contribute to tasks such as finding the root cause. It will be thought using either Minitab or Excel (to be agreed in advance) and the emphasis will be on what we can easily do.

Day 2
• Product Design, including: Components and applications, wall sections and profiles, webbing and thinning, chill marking, definition, reinforcing, finishing and trimming.
• Trouble shooting, including: Blistering, scorching, sticking, poor definition, webbing, warping, chill marking, thinning, tearing, sagging, contamination and static.
• Thermoforming materials, including: Material Characteristics, ABS, PMMA, PETG, HIPS, PC, PP, PE and PVC are covered.
• Multi-layer materials and feed stocks, inline processes.
• Practical Session
• Discussion/ Q&A Session
The centre is also equipped with a Formech 300XQ thermoforming machine, which will be used for the practical element of the course

Who Should Attend?
The course introduces the subject of thermoforming technology. The course will be useful to existing or new vacuum forming machine setter operators, plastic product designers, vacuum form tool manufacturers, designer makers, product engineers (eg, medical production / product development) and those undertaking new plastic product development and prototype.manufacture.