Education and Training Prospectus
EDUCATE
INSPIRE
IMPROVE
About The Manufacturing Institute The Manufacturing Institute is an independent charity founded to educate, inspire and improve manufacturers, their employees and the general public. We deliver a wide range of high quality education, training and consultancy services which builds operational excellence in some of the world’s most effective manufacturing companies. Profits from our trading activities are used to fund a number of innovative charitable projects designed to improve the image and perception of the manufacturing sector amongst young people and drive grass roots innovation in the community. During the last decade we have helped over 9,000 manufacturers to improve their processes and delivered improvements worth over £1.1bn. To find out how we can help you, please call us on +44 (0) 161 875 2525, email: info@manufacturinginstitute.co.uk or visit www.manufacturinginstitute.co.uk
Contents 1. Welcome 2. Our partners 3. Manufacturing Leaders
•
MSc in Manufacturing Leadership
•
Professional Diploma in Manufacturing
•
Certificate in Manufacturing Operations
•
Certificate in Manufacturing Management
•
Shingo Prize Model Training Workshops
15. Manufacturing Managers
•
Six Sigma Green Belt
•
Accelerated Route to Lean Manufacturing
•
Lean Leadership
•
Lean Immersion Day
23. Manufacturing Team Members
•
Six Sigma Yellow Belt
•
Team Leader Development
•
Lean Office Foundation
•
Lean Office Champion
•
NVQ in Business Improvement Techniques
Foreword It is my personal belief that the future of manufacturing
To find out more about our programmes,
relies upon investment in people.
please read on and then call our team on 0161 875 2525 to discuss your particular
Our highly acclaimed education and training courses
individual and business needs.
help to create successful leaders and successful manufacturing businesses. They are built on our unrivalled experience of helping over 50,000
Best wishes,
manufacturing employees to develop their skills and knowledge. From factory floor to board room, we have a tremendous track record of providing high-impact programmes. In addition to our range of public courses we also develop and run in-company programmes tailored to specific
Julie Madigan
skills development needs. All courses are designed to
Chief Executive
provide your employees with the tools and expertise they need to tackle both the day to day challenges and deliver against strategic goals.
In-company courses In-company courses delivered by Manufacturing Institute practitioners are an ideal alternative for businesses that have very specific training requirements. We are able to offer a ‘flexible’ service that combines elements from various courses and aligns the programme to your corporate objectives. There are many benefits to developing your own in-house course: • Programmes can be adapted to address particular needs and include organisation-specific information • Courses can cater for larger volumes of learners • Time away from the operation is minimised • Employees are given clear and consistent direction • Delegates can openly discuss current business challenges • Courses provide an ideal forum for staff to input their thoughts and ideas
“One of the main reasons we chose The Manufacturing Institute to support us on our lean journey is that they’re able to provide such a broad range of services - and good lean training is crucial to us. We have trained people at all levels and in many different roles in the company to be able to understand and apply lean tools and principles in improving their own processes. This means that we’re able to set our direction, make our plans and execute them.” Michael Hutchman, Lean and Production Controller Iggesund Paperboard
Our partners The Manufacturing Institute has a unique partnership with both leading manufacturers and prestigious academic institutions, including five star rated UK universities and leading international establishments. These partnerships allow us to bring together visionaries from the best faculties to deliver leading-edge and highly relevant thinking across our courses, combining practical skills with leading business techniques and principles.
Our university partners include:
Course leaders The Manufacturing Institute selects the very best education and training from around the world in order to bring world-class manufacturing education to the Northwest. Course leaders are exceptional professionals and academics with enviable international track records. Members of our global team are selected for their knowledge, experience and ability to challenge and broaden the thinking of our manufacturing students, providing them with the key elements that are vital for building operational excellence. Our delivery team has 20 years experience of delivering development and improvement programmes to manufacturers of all sizes, across a wide range of sectors. Our high-impact technical and leadership programmes are delivered by handson manufacturing professionals with a proven track record of helping manufacturing companies make significant and lasting improvements to their businesses. As educational partner for the Shingo Prize, training content reflects our experience of global operational excellence.
“I’ve been involved in the MSc in Manufacturing Leadership since its inception. Our goal has been to equip developing industrial leaders with the tools, insights and analytical frameworks to underpin the next stages of their careers and deliver real impact and benefit in their companies. Having seen this progress and growth first-hand, I’m convinced the programme is really delivering the vision.” Dominic Oughton, Principal Industrial Fellow, Institute for Manufacturing Education and Consultancy Services, University of Cambridge
2
Manufacturing Leaders
The MSc in Manufacturing Leadership This unique MSc programme develops high-calibre manufacturing professionals with the ability to create wealth in manufacturing. It is designed to develop individual leadership qualities as well as provide the essential knowledge required to build a world class manufacturing business. The MSc in Manufacturing Leadership has been developed by industry leaders and is delivered by a team of global experts. With accreditation and specialist input from Lancaster University Management School, a triple-accredited, world-ranked management school, this prestigious programme is aimed at those with the highest potential for achievement within the industry.
What are the benefits to the company?
How does it work?
Course outline
• Development of a multi-disciplinary approach to manufacturing enterprise management in order to create wealth.
The course is taught part-time over a two year period followed by a further eight months to complete a dissertation. The programme comprises six modules each delivered by a senior academic or industrialist. Modules contain four workshops and three action learning sets.
Modules 1 Leadership: Leadership styles in different stages of organisational development, mechanisms of good communication, change management and creating a shared vision, building effective teams, motivation and managing performance.
• Adoption of world class manufacturing principles and leading edge thinking. • Transfer of knowledge from leading manufacturing experts and industry peers. • Implementation of seven in-house business improvement projects. • Significant financial benefits expected by the end of the programme. • Formal development of high calibre individuals.
Who is the course designed for?
Workshops provide the opportunity for intensive learning and discussion while action learning sets are designed to address the individual manufacturing challenges and issues raised by the group. These sessions help participants to better understand the core learning and how to apply the knowledge gained.
Current or future business leaders in small and large companies.
Course prerequisites: A degree or equivalent professional qualification is desirable. Students who demonstrate the enthusiasm and ability to study at Masters level will also be considered. In the interest of continuous improvement, all outline syllabuses may be subject to modification.
3
Module 2 Global markets and future manufacturing: Global markets – trends and drivers, competitive strategies for the 21st Century, alternative models for future manufacturing. Module 3 Generating wealth in manufacturing: Measures for business success and manufacturing performance, strategic business planning, financial modelling and management accounting. Module 4 World-class manufacturing practices: Best practice and benchmarking, principles of lean and agile manufacturing, supply chain management. Module 5 Manufacturing enterprise creation and development: Creating value for customers and shareholders, developing and deploying strategy. Module 6 Innovation: Understanding the innovation lifecycle, convert creativity into competitive advantage, project and risk management.
Masters dissertation Following the successful completion of the six taught modules, delegates complete a dissertation based on research into a real problem or issue faced by the delegate’s business. This requires the student to exhibit informed and critical application of knowledge, techniques and principles acquired during the programme. The dissertation phase incorporates a compulsory taught Research Methods module.
“The MSc course massively broadened my thinking on the criticality of leadership in creating world class organisations. The modules are structured to provide a deep knowledge of some key elements that are fundamental to building for success. Getting exposure to a great amount of research material and interaction with colleagues’ experiences from other industries provides a great learning environment which, although is hard work and takes a lot of commitment, can also be great fun and is extremely rewarding.” Chris Teegan, General Manager - Kerry Foods
Course Duration:
2 years, 8 months
Public Course:
Yes
In-company course:
The taught MSc course can also be delivered as an in-company development programme
Tel: +44 (0) 161 875 2525
www.manufacturinginstitute.co.uk
4
Manufacturing Leaders
The Professional Diploma in Manufacturing The nationally recognised Professional Diploma in Manufacturing is a results driven course geared towards developing people and their management skills. Diploma graduates consistently demonstrate greater confidence, motivation and effectiveness and deliver real benefits to their companies. The breadth and depth of the Diploma sets it far apart from other high level manufacturing education and development programmes. As well as learning about the latest manufacturing techniques, students learn how to develop themselves as effective leaders and gain a wider appreciation of their business. The course is designed and driven by manufacturers, exclusively for manufacturers. It is taught by leading experts from industry and academia and is quality assured by a consortium led by the the University of Manchester.
What are the benefits to the company?
Course prerequisites:
Course outline
• Significant improvement in business performance through the application of new skills.
The course is open to anyone with five or more years of manufacturing experience, irrespective of formal qualifications.
Manufacturing education modules: Manufacturing strategy, manufacturing processes and types, gaining and keeping control of the manufacturing environment, supply chain management, the role of projects in manufacturing improvement, simplifying and improving the production process, automation and the use of computer systems.
• Students are required to communicate across various functions and at multiple levels – enabling them to understand the ‘bigger picture’. • Provides an effective succession planning pathway and formal development of high calibre individuals. • Practical course assignments designed to deliver immediate benefits back into the company.
Who is the course designed for? The Diploma is designed for managers who typically have more than five years practical manufacturing experience, may have some formal qualifications - although this is not essential - and are required to manage people, processes and budgets in order to improve manufacturing performance. Typical students include: production, manufacturing, works and operations managers; engineering managers and team leaders.
How does it work? The Diploma can be accommodated into a busy manufacturing environment. Timetabling aims to minimise workplace disruption. The programme consists of 14 taught modules each delivered over a sixweek period. Most modules involve three or four study days (usually on Thursday and Friday). Typically the course requires approximately 25 hours per month of home study. All modules use case studies and practical industrial examples, and are assessed by a 2,500 word in-company assignment. At the end of the programme students are required to undertake an in-company improvement project. This is designed to drive the skills and knowledge acquired back into the business as quickly as possible. The Diploma offers a progression route to the MSc in Manufacturing Leadership and other Masters programmes.
5
Students will learn how to implement a manufacturing strategy and manage a successful manufacturing operation. Personal effectiveness modules: Leadership and managing change, developing others, developing yourself. Students will be taught tools for influencing, team building and managing change at work. They will gain a deeper understanding of themselves and their personal dynamics within the workplace. Business awareness modules: The future manufacturing enterprise, global competitiveness, customers and markets, finance and accounting for manufacturing managers. Students will find out what critical responses are required across the business to flourish in a challenging competitive environment.
“I gained many personal benefits from attending the Diploma course. It has given me the confidence to talk knowledgeably to people at any level and has developed my understanding of manufacturing process types and tools to improve them. The incompany project identified improvements that are expected to double the uptime in the extrusion department.� Stuart Devlin-Gray, Process Improvement Manager - James Dawson Global Hose
PLAY
Course Duration:
2 years, 4 months
Public Course:
Yes
In-company course:
Modules, or combinations of modules from the Diploma can be delivered as in-company programmes
Tel: +44 (0) 161 875 2525
www.manufacturinginstitute.co.uk
6
Manufacturing Leaders
The Certificate in Manufacturing Operations The Certificate in Manufacturing Operations is a derivative of our highly acclaimed Professional Diploma in Manufacturing. The course teaches the critical manufacturing methods and techniques required to deliver improved customer service, increased sales and reduced costs. It is delivered by leading academics and manufacturing experts and is quality assured by The University of Manchester. The Certificate is an ideal alternative or first step towards the full Diploma for students that need flexibility in their development programme.
What are the benefits to the company?
Course prerequisites:
Course outline
• Significant improvement in business/departmental performance through the application of newly acquired technical and management skills.
This Certificate programme is open to anyone with several years manufacturing experience, irrespective of any formal qualifications.
Modules:
• Formal development of high calibre individuals. • Provides an effective succession planning tool. • Practical course assignments designed to deliver immediate benefits back into the company.
Who is the course designed for? As with the Diploma, the Certificate is designed for managers who: • Have several years or more of practical manufacturing experience. • May have some formal qualifications. • Need to manage people, processes and budgets. • Are tasked with improving manufacturing process performance in leaner organisations. Typical students include: production, manufacturing, works and operations managers; engineering managers and team leaders.
7
How does it work? The programme consists of seven self-contained modules each delivered over a six-week period. Most modules involve three or four day taught sessions (normally on Thursday and Friday). In addition, approximately 25 hours per month home study is required. All modules rely heavily on case studies and practical industrial examples, and are assessed by a 2,500 word in-company assignment. Students on the Certificate in Manufacturing Operations are required to have an in-company mentor who can support them through the modules and completion of assignments. Mentors act as the bridge between the students’ learning on the programme and the workplace, facilitating the transfer of learning so that the student can apply it in their own workplace.
Students will learn how to implement a manufacturing strategy and manage a successful manufacturing operation. On completion of the course, they will be able to use the knowledge gained to develop appropriate manufacturing strategies for a business. The course covers a range of subject areas including: • Manufacturing strategy. • Manufacturing processes and types. • Gaining and keeping control of the manufacturing environment. • Supply chain management. • The role of projects in manufacturing improvement. • Simplifying and improving the production process. • Automation and the use of computer systems.
“Business improvement activities carried out using the knowledge and skills acquired from the certificate have resulted in a significant reduction in our product failure rate, which has in turn created savings of in excess of £50,000 per annum. An increase in output from one of our key bottleneck machines has generated labour efficiency savings of £8,000 per annum.” James Tiernan, Manufacturing Manager RS Clare & Co Ltd
Course Duration:
10 months
Public Course:
Yes
In-company course:
No
Tel: +44 (0) 161 875 2525
www.manufacturinginstitute.co.uk
8
Manufacturing Leaders
The Certificate in Manufacturing Management The Certificate in Manufacturing Management is a derivative of our highly acclaimed Professional Diploma in Manufacturing. The modules taught in this course aim to develop management skills and enhance appreciation of the wider manufacturing environment so that students can identify opportunities for business improvement and growth. There is particular focus on personal effectiveness and the development of self and others as a means of achieving a step change in performance. It is delivered by leading academics and manufacturing experts and is quality assured by The University of Manchester. The Certificate is an ideal alternative or first step towards the full Diploma for students that need flexibility in their development programme.
What are the benefits to the company?
Course prerequisites:
Course outline
• Significant improvement in business/ departmental performance through the application of newly acquired technical and management skills.
This Certificate programme is open to anyone with several years manufacturing experience, irrespective of any formal qualifications.
Personal effectiveness modules:
• Formal development of high calibre individuals.
How does it work?
• Provides an effective succession planning tool. • Practical course assignments designed to deliver immediate benefits back into the company.
Who is the course designed for? As with the Diploma, the Certificate is designed for managers who: • Have several years or more of practical manufacturing experience. • May have some formal qualifications. • Need to manage people, processes and budgets. • Are tasked with improving manufacturing process performance in leaner organisations. Typical students include: production, manufacturing, works and operations managers; engineering managers and team leaders.
9
The programme consists of seven self-contained modules each delivered over a six-week period. Most modules involve three or four day taught sessions (normally on Thursdays and Fridays). In addition approximately 25 hours per month home study is required. All modules rely heavily on case studies and practical industrial examples, and are assessed by a 2,500 word in-company assignment. Students on the Certificate in Manufacturing Management are required to have an in-company mentor who can support them through the modules and completion of assignments. Mentors act as the bridge between the students’ learning on the programme and the work place, facilitating the transfer of learning so that the student can apply it in their own workplace.
leadership and managing change, developing others, developing yourself. • Understand the link between the changes in the global business society and changes within organisations. • Provide tools for influencing, team building and managing change at work. •
Provides the opportunity for self-analysis allowing students to gain a deeper understanding of themselves and their personal dynamics within the workplace.
Business awareness modules: the future manufacturing enterprise, global competitiveness, customers and markets, finance and accounting for manufacturing managers. • Understand the impact of competitive pressures resulting from the globalisation of markets and supply chains. • Gain a broad appreciation of the role of marketing and sales within the manufacturing supply chain. • Understand the critical responses required to flourish in such a challenging environment.
“As a department we have seen month on month productivity improvements and overall improvements on machine efficiency purely by applying the teachings from the certificate course. The shop floor buy in has ensured that we maintain standards and look to continually improve.� Martin Wild, Production Manager Federal-Mogul Friction Products
Course Duration:
10 months
Public Course:
Yes
In-company course:
No
Tel: +44 (0) 161 875 2525
www.manufacturinginstitute.co.uk
10
Manufacturing Leaders
Shingo Prize Model : The Principles of Operational Excellence Training Workshop The Shingo Prize is the premier award for operational excellence. Its purpose is to recognise world class business performance and accelerate operational excellence by the application of lean principles, systems and tools through a culture of learning and understanding. The Principles of Operational Excellence Training Workshops present a unique opportunity to learn how to use the Shingo Model assessment methodology to drive transformation and achieve world-class business results. The one-day workshop introduces the principles of the Shingo Model and is ideal for businesses embarking on a transformation journey, while the two-day course encompasses ‘Go-See’ visits to manufacturing sites and provides the necessary awareness to allow self-assessment of your own organisation.
What are the benefits to the company?
How does it work?
Course outline (2 day workshop)
• Application of the Shingo Prize Model as a guide to lean transformation.
The course is available in a one-day or twoday format. The one-day workshop provides an introduction to Shingo principles through an intensive classroom programme, while the two-day workshop combines practical assessments of the business through structured assessment visits to the workplace.
Day One
• Development of an organisational culture that creates enduring continuous improvement. • Opportunity to see operational excellence in action at a world-class site and undertake a practical assessment within the host business. • Improvement of company core business processes.
Who is the course designed for? This training is designed for senior managers responsible for introducing and managing lean transformation across their organisation.
Course prerequisites: To get the most benefit from this course, you should already have embarked on a lean or operational excellence journey and be ready to apply management-led operational excellence across the organisation.
11
By the end of the 2 day course, delegates will be able to: •
Assess alignment and manage the process of realignment by embedding lean principles into work and management systems.
•
Complete a self-assessment of your organisation that will clearly identify areas for focus and improvement across the entire business.
• The Shingo Prize context. • Introduction to the model, enablers and continuous improvement. • Principle focus, systems and tools focus. • Principle driven behaviour. • Principle based assessment: Go and see (first practical exercise).
Day Two • Principle based assessment: Go and see (second practical exercise).
• Understand the Shingo Model as well as the underlying principles and assessment models for the Shingo Prize.
• Principle based assessment: Go and see (third practical exercise).
• Complete a Shingo Prize Achievement Report.
• Achievement report writing.
In addition to the taught course, delegates will be encouraged to share their ideas and experiences and will also have the opportunity to access expert advice on company specific issues during one-to-one clinics at the end of each day.
• Fundamentals of the site examination process.
“The Nobel Prize for Operational Excellence” Business Week
Course Duration:
1 or 2 days
Public Course:
Yes
In-company course:
Yes
Tel: +44 (0) 161 875 2525
www.manufacturinginstitute.co.uk
12
Manufacturing Leaders
Shingo Prize Model: The Dimensions of Operational Excellence Workshops Challenging for the Shingo Prize represents an opportunity to benchmark business performance internationally against world-class organisations through a well respected and independent pool of international examiners. The ‘Dimensions of Operational Excellence’ is a series of four inter-related programmes reflecting the four dimensions of the internationally recognised Shingo Model for Operational Excellence: Cultural Enablers, Continuous Process Improvement, Enterprise Alignment and Business Results.
What are the benefits to the company?
How does it work?
Course outline
• Application of leading-edge thinking to transform business performance.
To get the most benefit from this course, you should already have embarked on a lean or operational excellence journey and be ready to apply management-led operational excellence across the organisation.
Cultural Enablers will help you establish and embed a
• Use of structured tools to analyse the business and create personal and group action plans, delivering the thinking immediately back into the organisation. • Implementation of key transformation principles that are aligned with core values and behaviours, and which develop a progressive organisational culture. • Knowledge-transfer between experienced senior managers from the manufacturing sector – an opportunity to learn from the experiences of others.
Who is the course designed for? This training is designed for senior managers responsible for introducing and managing lean transformation across their organisation.
13
How does it work? There are four two-day workshops on each dimension, which use taught methods and interactive exercises to help explore current thinking in an open yet confidential environment. They also provide an effective forum for individual reflection on personal and leadership team behaviours. The programme is flexible in that delegates may attend all four workshops or just choose those that are most relevant to their business.
culture based upon the basic guiding principles of ‘respect’ and ‘humility’, anchoring the attitudes, behaviour, values, vision and goals. The pre-workshop business assessment enables delegates to understand the current state of the organisation and develop personal and collective team plans through the course of the programme. Continuous Process Improvement shows delegates how to build on a basic ‘tools and techniques’ lean programme to create a systems approach to improvement across the whole enterprise – bringing together customer relations, management, product and service development, operations and supply. Enterprise Alignment demonstrates the value and methods for achieving constancy of purpose throughout the organisation. The workshop examines how the key themes of vision and strategy, systemic thinking and ‘seeing reality’ create alignment and how policy deployment that is based on ‘scientific thinking’ and involvement can provide clearer direction and focus for all employees. Business Results explains how organisations can create value by focusing resource and improvement effort on the elements of the business that customers are willing to pay for. Measurement of ‘value components’ - people development, quality, delivery, cost, financial impact and competitive impact – provides a performance baseline and an opportunity to increase company value by optimising each of these drivers.
z
“To know how is not enough. You need to know why.” Dr. Shigeo Shingo
Course Duration:
2 days per workshop
Public Course:
Yes
In-company course:
Yes
Tel: +44 (0) 161 875 2525
www.manufacturinginstitute.co.uk
14
Manufacturing Managers
Six Sigma Green Belt Our Six Sigma Green Belt programme is a practical, hands-on course focused on eliminating waste and increasing efficiency across the whole operation and along the supply chain. Qualified Six Sigma Green Belt practitioners have the skills and expertise to apply sophisticated improvement tools, change behaviours and transform business performance. Practitioners typically generate cost savings of £25,000 - £250,000 through the Six Sigma projects they implement. The programme is delivered by experienced Master Black Belt practitioners who also offer mentoring, support and advice.
What are the benefits to the company?
Course prerequisites:
Course outline
• Increased efficiency to drive up profitability or offset cost increases in other areas e.g. raw materials.
Attendees should have a basic knowledge of lean tools and techniques and experience within a manufacturing environment.
Part 1 (3 days)
• A more efficient operation creating competitive advantage. • Culture and practices changed to sustain improvement activity and long term financial benefits. • Recognised Green Belt certification adds credibility to your team and business within the industry. • Development of strong leadership, problem solving and change management skills.
Who is the course designed for? Managers and team leaders in the following roles: • Continuous improvement. • Production. • Manufacturing. • Operations. • Quality.
15
How does it work? The programme is delivered through practical group and individual exercises, worked examples and seminar type case discussions. The ‘Train-Learn-Apply-Share’ cycle is used to maximise student understanding and value delivered back into the business. This methodology can increase the financial return fourfold when compared to a traditional classroom-based course. To get the most benefit from the programme, candidates should be fully prepared before each session, contribute to discussions and be ready to share their own experiences. To achieve Green Belt certification students must also complete an incompany project and submit written reports for assessment, detailing the quantified benefits they have delivered – all of which are signed off by their sponsoring manager.
Six Sigma overview, how Six Sigma links with lean, critical to quality/voice of the customer, introduction to the Six Sigma DMAIC process, basic statistics and principles of variation, introduction to Minitab, project charters, cause and effect analysis, process mapping, data collection. Part 2 (3 days) Project progress reviews, gauge R&R, process capability analysis, analysis of variance, graphical analysis of input/output variables, stratification techniques, confidence levels, using the data to change behaviours. Part 3 (4 days) Project progress reviews, introduction to hypothesis testing (Anova, Regression, Chi Squared, T-Tests), design of experiments, generating and selecting solutions, optimisation of critical x’s, managing project and team, mistake proofing, process control, how to make Six Sigma sustainable.
“While we gather production data on a daily basis we were not using it as effectively as we could to reduce process variation so we chose The Manufacturing Institute to deliver green/yellow belt training to all management and process engineers. Since completing the in-house Six Sigma training, the team at Presspart has implemented a number of improvement projects, which have delivered a variety of tangible benefits.� Paul Gregson, OPEX (Operational Excellence) Leader Presspart Manufacturing
Course Duration:
10 study days
Public Course:
Yes
In-company course:
Yes
Tel: +44 (0) 161 875 2525
www.manufacturinginstitute.co.uk
16
Manufacturing Managers
The Accelerated Route to Lean Manufacturing Accelerated Route to Lean Manufacturing provides proven, practical toolkits for speedy bottom-line gain. This is a results-driven programme for those who want to become champions of lean manufacturing within their own workplace. The programme focuses on eliminating waste and driving up efficiency across the total manufacturing process - from supplier to customer. It draws on the specific issues students face every day to make this course 100% relevant to every manufacturer. Over 600 manufacturing professionals have completed Accelerated Route to Lean Manufacturing and applied their learning to create millions of pounds worth of productivity improvements.
What are the benefits to the company?
Course prerequisites:
Course outline
• Rapid transfer of skills and know-how to deliver immediate business benefits.
A desire to drive changes in a manufacturing environment.
Modules:
• Development of in-house expertise to create sustainable and tangible benefits.
How does it work?
• Improved understanding of what best-practice really means from an exclusive visit to a world class manufacturing site.
After just 12 weeks students will be able to put their knowledge into practice and realise some significant business improvements. Our ‘learn by doing’ approach is designed to maximise the understanding and impact of the course and combines practical forums with classroom based sessions.
• Increased credibility with suppliers and customers if Lean Manufacturing Fellowship is attained.
Who is the course designed for? The programme is geared towards individuals with responsibility for productivity and performance improvement in small and large companies.
17
An online lean learning portal is available for six months and provides a wealth of additional resources and information for the student and the sponsoring business. On completion of the course, students can choose to participate in an evaluated in-company improvement project, which is supervised by a Manufacturing Institute practitioner. Successful evaluation of this project can result in being awarded a Fellowship in Lean Manufacturing.
• Lean thinking and awareness provides an understanding of the guiding principles of lean manufacturing. • World class manufacturing – people and process site visit exposes the link between culture change and continuous improvement. •
Value stream identification and mapping (VSM) teaches students the concept of value streams, why the identification and mapping of value streams is important and how to value stream map.
•
Process mapping and blitz events, layout and cell design demonstrates two popular types of process mapping techniques. Students will also be shown the importance of leadership in fostering change.
• Problem solving and quality teaches the tools and techniques of quality management and problem solving. •
Build to plan shows why we plan and schedule. It explains the differences between planning and scheduling and why the achievement of the shortterm schedule is so vital to lean applications.
•
Workplace organisation and equipment effectiveness helps students to understand how 5S supports flow and standardisation. Students will also be taught Overall Equipment Effectiveness and Total Productive Maintenance.
•
Lean implementation demonstrates the need for a lean implementation strategy and presents a number of approaches and frameworks that have been used successfully by other organisations.
“When I was offered the role of continuous improvement facilitator my production manager enrolled me on the Accelerated Route to Lean Manufacturing course as we both felt this would equip me with the tools and techniques needed in my new role. As part of my work on the course, I implemented a number of productivity and stock reduction initiatives, which have generated over £60,000 of savings for the business.” Joan Robinson Continuous Improvement Engineer – Tritech International Ltd
PLAY
Course Duration:
12 weeks at 1 day per week
Public Course:
Yes
In-company course:
Yes – bespoke programmes can be created for in-company delivery
Tel: +44 (0) 161 875 2525
www.manufacturinginstitute.co.uk
18
Manufacturing Managers
The Lean Leadership Programme Most improvement initiatives fail because the roles of leadership and culture have not been considered. Lean Leadership is the only top-level course for senior managers and directors who are looking to develop, implement and lead a lean strategy. The programme provides the strategic understanding and leadership skills required to drive the successful implementation of lean manufacturing across the business.
What are the benefits to the company?
Course prerequisites:
Course Outline
• Transfer of knowledge from leading manufacturing experts who have implemented lean transformations.
None.
Modules are designed to provide an insight into key improvement tools and demonstrate the importance of effective leadership skills.
• Creation of a top level lean strategy to ensure programme success and generate tangible benefits. • Skills development of business leaders with overall responsibility for operational performance improvement. • Understanding of the change management and cultural factors that support long-term, sustainable improvements. • Enables a company-wide approach to change and improvement that everyone is bought into.
Who is the course designed for? The course is aimed at top-level executives in manufacturing companies who want to develop a lean strategy for their organisation.
19
How does it work? The course will answer the following questions: • How do I foster the right culture for a lean organisation? • How do I manage resistance to change within the organisation? • What are the business requirements for a successful lean implementation? • How can I develop a business strategy that integrates lean principles? • How will I calculate the potential business-wide benefits of a lean strategy? •
What are the critical success factors in lean implementation projects and common reasons for failure?
Modules 1 and 2: Lean leadership – these modules provide the delegates with an insight into how exceptional leadership is essential as part of the strategic change process. Module 3: A best practice factory visit exhibits how culture can be successfully changed within a business. Module 4: Lean accounting shows the harmful effects of traditional cost accounting and how flow accounting can aid decision making. Module 5: Value stream mapping and change leadership for lean will give delegates an overview of the value stream mapping tool, lean maturity assessment and policy deployment.
“The improvements made in the pilot area alone have increased throughput by over £400,000, improved delivery performance by 10% and given us the confidence to begin to extend lean to the whole site.” Michael Hutchman Lean and Production Controller – Iggesund Paperboard
Course Duration:
5 days
Public Course:
No
In-company course:
Yes
Tel: +44 (0) 161 875 2525
www.manufacturinginstitute.co.uk
20
Manufacturing Managers
Lean Immersion Day Our highly-popular Lean Immersion Days offer delegates unique lean learning experiences at world-class manufacturing sites. Delegates will gain an exclusive insight into the best in class manufacturing practices adopted by leading businesses such as Jaguar Land Rover and Leyland Trucks. The visits are hosted by members of the senior management teams who discuss both the process and management challenges they faced in the journey to becoming a centre of excellence. The Lean Immersion Day is ideal for companies that are in the early stages of their lean journey and who wish to gain a better understanding of what operational excellence looks like in practice. It provides valuable lessons on how to lead a lean improvement programme and foster a continuous improvement culture.
What are the benefits to the company?
Course prerequisites:
Outline Agenda
• Learn the what and the how of continuous improvement.
None.
9.00
Welcome and introductions.
How does it work?
9.15
The lean journey so far.
10.15
Break.
During the day delegates will tour the operation to see the application of lean techniques in practice. They will also see several case studies of projects which have made significant impacts on cost, quality and delivery.
10.30
Production area tour.
12.15
Lunch.
Networking and Q&A sessions throughout the day provide excellent opportunities to obtain advice and guidance from highly experienced manufacturing professionals with impressive track records of delivering operational excellence.
15.00 Lean leadership behaviours.
• Avoid the common pitfalls of continuous improvement initiatives to ensure project success and maximise business benefits. • Immediate transfer of knowledge from world-class manufacturers back into the business. • Access to leading manufacturing professionals for help and advice on current challenges. • Opportunity to network with other manufacturers and share best practice.
Who is the course designed for? The day can accommodate all levels from senior managers to line managers and is relevant to any small, medium or large company.
21
13.00 Tour of other departments. 14.15 Overview of projects and benefits.
15.30 Q&A session. 16.00 Close.
Course Duration:
1 day
Public Course:
n/a
In-company course:
n/a
Tel: +44 (0) 161 875 2525
www.manufacturinginstitute.co.uk
22
Manufacturing Team Members
Six Sigma Yellow Belt The Six Sigma Yellow Belt course is designed to equip delegates with the knowledge and skills required to maximise their contribution to Six Sigma or Lean Sigma projects and be part of a high-impact Six Sigma team. Robust data analysis and statistical processing is key to Six Sigma. As much of the data collection and measurement is carried out by the wider Six Sigma team, a good understanding of the methodology will help to ensure successful project delivery and generate tangible results. The training is delivered by qualified Six Sigma Black Belt practitioners who provide mentoring support throughout the programme.
What are the benefits to the company?
Course prerequisites:
Course outline
• Increased efficiency to drive up profitability or offset cost increases in other areas e.g. raw materials.
None.
Modules:
How does it work?
• Six Sigma overview.
• A more efficient operation creating competitive advantage. • Culture and practices changed to sustain improvement activity and long term financial benefits. • Development of a fully trained Six Sigma team that is equipped to deliver sustainable operational improvements and resulting benefits. • Recognised Yellow Belt certification adds credibility to your team and business within the industry.
• The link of lean. • Project selection.
The training occurs in a single block of 2 days and is extremely interactive. Delegates are expected to contribute to discussions and share their own experiences throughout the training, which includes:
• Project definition and chartering.
• Practical group and individual exercises.
• Control charting and statistical process control.
• Worked examples.
• Measurement systems evaluation.
• Seminar type case discussions.
• Capability analysis.
• Process mapping. • Cause and effect and failure mode effects analysis. • Basic statistics and principles of variation.
• Identifying the critical x’s.
Who is the course designed for?
23
• The basics of process control.
This course is suitable for any team members of Six Sigma or lean improvement projects – regardless of function or seniority - who need a basic understanding of ‘DMAIC’ methodology.
What is Six Sigma?
DMAIC project methodology has five phases: Define, Measure, Analyse, Improve, Control.
causes of defects and minimising variability in manufacturing and business processes.
Originally developed by Motorola, Six Sigma uses a robust data-based approach to drive continuous improvement and achieve transformative changes in business performance. Six Sigma seeks to improve the quality of process outputs by identifying and removing the A structured methodology is used to increase customer satisfaction and delivery performance, drive out waste and reduce cost and lead times.
“Since attending the two day Six Sigma Yellow Belt course we now have a strong, developing structure of 27 Yellow Belts and four Green Belts all involved in active projects. Having a foundation of Yellow Belt knowledge is fundamental in providing the critical mass and support structure for the Green Belts to drive and sustain the DMAIC approach to complex problem solving.” Mark Davidson, Special Projects Manager – Innovia Films
Course Duration:
2 days
Public Course:
No
In-company course:
Yes
Tel: +44 (0) 161 875 2525
www.manufacturinginstitute.co.uk
24
Manufacturing Team Members
The Team Leader Development Programme The Team Leader Development Programme is a high impact course designed to shake up team performance. This down-to-earth programme helps first line managers to improve management and lean manufacturing skills, giving them the tools to get more from their teams and add extra value to the business. As one of our most popular courses, the Team Leader Development Programme has helped more than 800 manufacturers apply their learning to lead operator teams in a lean manufacturing environment. The course is run by highly competent manufacturing professionals with a track record of developing high performing team leaders.
What are the benefits to the company?
Course prerequisites:
Course outline
• Immediate application of skills learned to improve operational performance and bottom line benefits.
No formal qualifications required.
• Manager-Mentor Session: understanding the role in supporting the delegates throughout the duration of the programme.
• Development of home-grown talent within course groups and their teams. • Support for succession planning. • Dissemination of lean manufacturing best practice within the organisation. • Improved confidence and ability of individuals to create and lead high-performance teams. • Access to an award winning manufacturing site to observe best in class.
Who is the course designed for? First line managers who are responsible for leading and working in teams, problem solving and improving day-today factory floor processes. Typical students include: team leaders, charge or leading hands; area, shift, cell or group leaders; first line managers; production or logistics supervisors; and production operatives.
25
How does it work?
• Programme modules. Students attend the course for one day per week over eight weeks. Each teaching day incorporates two half day modules. The format combines a best practice factory visit with workshops and seminars in order to develop a deep understanding of the subject areas. Students are encouraged to put their learning into practice in between sessions to gain maximum benefit from the course and build their confidence. In-company mentors provide guidance and direction to maximise the benefits to both the student and business.
• Visit to a Best Factory Award winning site. • Evaluation: an end of course presentation and review of learning.
Modules • From old to new style shop floor behaviour and culture. • Active leadership. • Understanding teams. • Communication and influencing skills. • Presenting to teams. • Managing your time and yourself. • Performance management. • Employment law. • Health and safety. • Overview of lean manufacturing. • Process improvement workshops.
“Over the last seven years as a direct result of this training programme our first line managers have implemented changes which have produced savings in production costs, improved product quality and Environmental, Health and Safety performance.� Charlie Hopcraft, Training and Improvement Facilitator - Johnson Matthey plc
PLAY
Course Duration:
8 weeks at 1 day per week
Public Course:
Yes
In-company course:
Yes - bespoke programmes can be created for in-company delivery
Tel: +44 (0) 161 875 2525
www.manufacturinginstitute.co.uk
26
Manufacturing Team Members
Lean Office Foundation Manufacturers have been using lean tools and techniques for many years to deliver productivity gains on the shop floor. Now the same lean principles have been adapted to improve back office processes in both manufacturing and service sectors. Lean Office Foundation provides a tried and tested tool kit to improve business processes and create significant improvements in service delivery. It is a results-driven training course for those who want to implement effective lean initiatives within the office environment and support organisation-wide improvement programmes.
What are the benefits to the company?
Course prerequisites:
Course outline
• Multiply the benefits of a factory based lean programme by extending activity into the back office to reduce cost and improve service.
None.
Module 1: Lean thinking and awareness: a brief history of lean, understanding what your customer values, lean principles exercise, the concept of waste within business processes, introduction to value streams.
• Equip office teams with the skills and know-how to continuously seek out improvements and efficiency gains. • Quick and simple path to boost business performance by achieving some immediate ‘quick wins’.
Who is the course designed for? Professionals based in the office with responsibility for service improvement and cost savings. Typical students include: office and departmental managers; team leaders and supervisors.
27
How does it work? This is a hands-on programme that can immediately be applied at work. Students learn by doing in practical forums combined with classroom based activities and discussion of case studies of successful lean office implementations. An optional in-company improvement project follows the course and enables the student to quickly apply the learning back into the business with mentoring support from a Manufacturing Institute practitioner. Classroom sessions are split over a number of weeks to give students the opportunity to put the theory into practice before progressing to learn more advanced tools and techniques.
Module 2: Mapping the process, work and waste in office processes, mapping the current state, identifying improvement opportunities, creating a future state, creating a continuous improvement culture and sustaining the changes. Module 3: Creating a productive workplace, measuring improvement, 5S in the office, visual management and visual display, IT in the office – 5S and systems. Module 4: Optimising flow, lean office simulation exercises, lean layout, case study – “The lean call centre”, running kaizen events in the office. Module 5: Delivering a quality service, fundamental concepts of quality, what is customer satisfaction?, error prevention versus error detection, problem solving approaches and methods, structured approach to the application of the 7 quality tools, what is a team and what makes it effective?
“A lean office can not only reduce waste and cut processing times and cost but it can also deliver a better and more responsive customer experience.” Peter Sussex, Principal Consultant – The Manufacturing Institute
Course Duration:
5 days
Public Course:
No
In-company course:
Yes
Tel: +44 (0) 161 875 2525
www.manufacturinginstitute.co.uk
28
Manufacturing Team Members
Lean Office Champion Lean Office Champion builds on the Lean Office Foundation course and focuses on developing the knowledge and capabilities required to initiate and lead an improvement programme in an office based environment. This short course is designed to give managers the confidence and ability to use lean principles in the office to reduce costs and deliver a better customer experience. By the end of the programme, students will understand how soft skills such as leadership, team working and coaching are applied to sustain improvement and long term benefits.
What are the benefits to the company?
Course prerequisites:
Course outline
• Develop lean office leaders who are equipped to deliver continuous improvement in their departments.
None.
Module 1: Leading change: leading change – group discussion, defining customer value and exploring the USPs of your organisation, Tesco case study on understanding what represents customer value, the Kano model explained, steps to delivering value through lean application in your businesses, measuring customer value with an overview of measures and performance, the importance of visual management in driving improvement, margin management: are all accounts good accounts?
• Multiply the benefits of a factory- based lean programme by extending activity into the back office to reduce cost and improve service. • Equip office teams with the skills and know-how to continuously seek out improvements and efficiency gains. • Provides a quick and simple path to boosting business performance by achieving some immediate ‘quick wins’.
Who is the course designed for? The programme is aimed at departmental managers, supervisors or project managers charged with developing and leading office-based or company-wide improvement programmes.
29
How does it work? The course combines presentations, case studies, multi-media and practical activities to develop an internal champion of lean.
Module 2: Understanding the process: the lean practitioner’s role, DWP Kaizen process, value stream identification, value stream mapping preparation, case study for value stream mapping. Module 3: Mapping the process: value stream mapping in the office, value stream mapping case study for group activity. Module 4: Managing the improvement process: project charters, design your own charter, A3 reporting – the key to success, managing the improvement process, holding effective meetings, RACI charts.
The concept of ‘lean office’ is often overlooked in favour of factory floor improvement initiatives. Many companies simply don’t realise the enormous gains to be had by applying lean thinking across the whole business.
Course Duration:
4 days
Public Course:
No
In-company course:
Yes
Tel: +44 (0) 161 875 2525
www.manufacturinginstitute.co.uk
30
Manufacturing Team Members
Business Improvement Techniques (BIT) NVQ – Levels 2 & 3 The Business Improvement Techniques NVQ programme provides industry standard National Vocational Qualifications centred on the proven tools and techniques of lean manufacturing based on the Toyota Production System. It is designed to support continuous improvement by promoting effective team working and developing lean skills across the wider workforce. The programme is aimed at production workers of all levels irrespective of their technical qualifications and empowers them to deliver lean improvements in their own workplace. It teaches them how to identify and eliminate waste, create flow and improve quality leading to greater efficiency and increased profitability.
What are the benefits to the company?
Course prerequisites:
Course outline
• Delivers sustainable productivity improvements and cost reduction through the application of learning in the workplace.
None.
Modules
How does it work?
• Complying with statutory regulations and organisational safety requirements.
• Promotes a safer, better organised workplace. • Provides a nationally recognised qualification. • Empowers the wider workforce to participate in lean initiatives. • Promotes effective team working and a culture of continuous improvement.
Who is the course designed for? Supervisors, team leaders and operators.
• Contributing to effective team working. The programme is based on national occupational standards and combines training with workplace assessment and final accreditation, as follows: 1. An assessment of each individual’s skills and preparation of personal learner plans. 2.
Knowledge training in Business Improvement Techniques delivered by an experienced lean practitioner (typically 18 hours).
3.
An assessment of each learner’s competency in the application of lean tools and techniques in their workplace.
4. Assessment over a period of six months. 5. NVQ level 2 or 3 awarded to successful learners.
31
• Applying workplace organisation techniques (5S/5C). • Applying continuous improvement techniques (Kaizen). • Creating visual management systems. • Applying problem solving techniques*. *Alternative units are available
The Manufacturing Institute is an approved centre for EAL - the leading awarding body for vocational qualifications in engineering and technology.
“Since 2009 we have completed 30 NVQ projects and 54 people have become certified in either level 2 or 3. Those people now continue to work as a team, meet on a regular basis and continue to carry out improvements within the factory, which include: • • • • • •
‘Not Right First Time’ reduced from 11% to 4% Increased people productivity from 44.2 to 47.47 Delivery schedule achieved increased from 66% to 100% Cost reduction of £1.41 per appliance Welder parts per hour increase from 100 to 112 Over processing on the welding process eliminated”
Tony Smith, Lean Improvement Engineer, Glen Dimplex Home Appliances
Course Duration:
3-6 months
Public Course:
No
In-company course:
Yes
Tel: +44 (0) 161 875 2525
www.manufacturinginstitute.co.uk
32
Education and Training Clients include:
To find out how we can help you call +44 (0) 161 8752525, email: info@manufacturinginstitute.co.uk or visit www.manufacturinginstitute.co.uk
EDUCATE
INSPIRE
IMPROVE