Engineering

 Lean manufacturing

Learning objective:
A Lean Enterprise delivers maximum value to its customers using the minimum amount of materials, labour, finance and other resources. 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


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 mins 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.