ETCAL Level 2 Certificate In Business Improvement Techniques

What you'll be able to do

• Know the principles of Total Productive Maintenance (TPM).
• Know the ways TPM can help improve the profitability of a business.
• Know the ‘5 pillars’ of TPM, and who needs to be involved in its implementation.
• Know what preparation is required prior to a TPM activity taking place.
• Know the health and safety requirements for the area, and the resources required for a TPM activity.
• Apply the practical steps of TPM.
• Know the 6 major losses, their impact on a business, and how they can be eliminated.
• Collect the information needed to calculate Overall Equipment Effectiveness (OEE).
• Know why it is necessary to audit TPM activities, and the techniques used.
• Carry out a TPM audit.
• Know what aspects of business performance can improve as a result of TPM.
• Know how TPM fits in with other lean business principles.

What you'll be able to do

• Know the principles of Flow Process Analysis, its benefits and use in a lean manufacturing environment.
• Establish ‘value added’ and ‘non value added’ activities.
• Know how Flow Process Analysis is applied to a part or process to help identify where waste or problem conditions occur.
• Construct a flow analysis sheet to map the process.
• Carry out a Flow Process Analysis on a chosen part, using appropriate tools and techniques.
• Produce a visual representation of a process using appropriate mapping techniques.
• Know the type of improvements that can be made to the process, with defined, quantifiable objectives and targets.
• Know the implementation issues that can arise as a result of proposed improvements.
• Produce a payback matrix or efficiency statement that prioritises and evaluates improvement opportunities.
• Know how Flow Process Analysis fits in with other lean business processes.

What you'll be able to do

• Know the principles of ‘Set up reduction techniques’, and how it can improve business efficiency and profitability
• Critically evaluate the changes that have been made, or are being proposed, to the set up activity
• Know the role and application of standard operating procedures in sustaining improvements
• Know how effective process set up and changeover techniques can build effective team working in the workplace
• Know how effective process set up and changeover techniques fits in with other lean business principles
• Know why a machine, process or operation can be selected for the improvement activity, and what range of improvements can be possible
• Know the difference between motion and work, and what is meant by value adding and non value adding activities
• Carry out the basic steps in a set up procedure
• Know the basic steps to be followed in a set up procedure aimed at streamlining the set up operation
• Know the preparation needed to be done prior to a set up reduction activity taking place
• Apply the practical steps of ‘set up reduction techniques’ using the ‘Single Minute Exchange of Dies’ (SMED) technique
• Apply effective problem solving methods and techniques to further improve the set up activity
• Set quantifiable targets and objectives for the improvement activity, and how they can be achieved

What you'll be able to do

• Recognise when to use kanbans as part of a stock control system
• Recognise when to use kanbans as part of a production control system
• Understand the development of work flow from traditional push systems
• Understand the development of work flow through visual pull systems
• Understand the development of work flow to continuous flow systems
• Recognise the various types of visual triggers that are used as a means of visual communication
• Create stock control triggers
• Understand how kanbans communicate the need for action
• Design and use a two bin system where the container acts as a trigger
• Understand how to use multiple containers to cope with high volumes
• Understand how to use multiple containers to cope with complex supply chains
• Understand how kanbans are important parts of pull systems
• Understand how to use input and output kanbans to create flow through a production area
• Understand how to use input and output kanbans to create flow through a series of processes
• Recognise the strengths of kanban systems
• Recognise the weaknesses of kanban systems

What you'll be able to do

• Define what lead time is
• Understand how lead time is used as an improvement tool in a lean business environment
• Understand how to identify the representative parts or processes that are suitable for the production of a lead time profile
• Understand the type of information required to compile a draft outline of lead time profiles
• Create a lead time profile for the part or processes that have been analysed
• Create a frequency diagram for the part or processes that have been analysed
• Understand how to fully analyse the current practice in order to identify potential improvements
• Recognise the type of improvements that can be made to reduce lead time
• Understand defined, quantifiable, objectives for improvements to reduce lead time
• Understand defined, quantifiable, targets for improvements to reduce lead time
• Understand the implementation issues that can arise as a result of proposed improvements to achieve a targeted lead time
• Understand how to plan the improvements needed
• Understand the consequences for the business of not being able to achieve the benefits of improvements
• Understand how Lead Time Analysis fits in with other lean business activities

What you'll be able to do

• Know the different types of team roles, and how they contribute to effective team working.
• Know how working relationships need to extend across appropriate work groups and departments.
• Identify individual strengths and weaknesses, and how they contribute to the effectiveness of the team.
• Know how individuals behaviour and appearance may be perceived by others.
• Know the importance of creating and maintaining effective working relationships.
• Know the types of problems and difficulties that can occur within team working relationships, and how they can be resolved.
• Know the importance of sharing knowledge, information, and performance measures within the team.
• Present information in an amicable and constructive manner, in relation to the team or individual circumstance.
• Use different types of communication methods, in order to keep others informed.
• Identify the mixture of skills and experience available within a team.
• Know how the mixture of skills and experience within a team, contributes to effective team working.

What you'll be able to do

• Know the importance and need to continuously improve productivity in the working environment.
• Know the types of improvement that can be made as part of continuous improvement.
• Know what is meant by the term ‘waste’ in business, and how it affects productivity.
• Contribute to the elimination of ‘waste’ in a workplace.
• Know what benchmarking is.
• Know the potential benefits of benchmarking.
• Identify the type of improvements that can be made in the workplace.
• Know the ‘12’ steps to carrying out a continuous improvement activity.
• Carry out a continuous improvement activity.
• Know the key performance indicators that are used to measure improvements.
• Know how performance indicators are applied, and the results visually communicated.
• Know the role of standard operating procedures in sustaining improvements.
• Know the importance of an appropriate environment for improvement.

What you'll be able to do

• Define what a work environment is
• Define what is meant by an organised working environment
• Identify the benefits that can be achieved by having an organised working environment
• Recognise the methods and techniques for workplace organisation
• Understand how the methods and techniques for workplace organisation are used
• Understand how the steps of workplace organisation are implemented
• Apply the first three steps of workplace organisation
• Understand the fourth and fifth steps of workplace organisation in order to sustain the workplace
• Understand the fourth and fifth steps of workplace organisation in order to improve the workplace
• Carry out a tagging exercise
• Understand how to redeploy non-essential items from the workplace
• Understand how to dispose of non-essential items from the workplace
• Understand why it is necessary to audit workplace organisation activities
• Recognise the tools and techniques that are used to audit workplace organisation activities
• Carry out a workplace organisation audit
• Understand how aspects of health may improve as a result of good workplace organisation
• Understand how aspects of safety may improve as a result of good workplace organisation
• Understand how aspects of team work may improve as a result of good workplace organisation
• Understand how workplace organisation fits in with other lean business techniques

What you'll be able to do

• Identify the selection of parts for improvement from within a chosen area or product range.
• Know the type of information required to select representative parts within a chosen area or product range.
• Group identified parts into appropriate part families.
• Group parts based on part shape, part size, the material used to manufacture the part, and the manufacturing process.
• Carry out an analysis of parts.
• Know the principles and process of carrying out an analysis.
• Know the difference between ‘lead time’ and ‘cycle time’.
• Know what is meant by the term ‘bill of materials’ for each of the representative parts.
• Know the importance of analysing and selecting parts for improvement.
• Know how the analysis and selection of parts for improvement fits in with other lean business techniques.

What you'll be able to do

• Know the types of problems that can affect a business, including operational, financial, and strategic problems
• Know the effects of unresolved problems on business performance, such as reduced productivity, increased costs, and decreased customer satisfaction
• Know the benefits of adopting a structured approach to problem solving, such as improved efficiency, better decision-making, and enhanced teamwork
• Know the techniques available to help identify, contain, and resolve problems in the workplace, such as root cause analysis, brainstorming, and the 5 Whys
• Apply the appropriate problem solving technique to identify the root cause of a problem
• Know how the appropriate corrective actions are determined, selected, and implemented to resolve problems
• Know the tools and techniques available to prevent the recurrence of a problem, such as process improvement, standard operating procedures, and training
• Capture improvement opportunities, and the actions needed to carry out the improvement effectively
• Know how effective problem recognition and problem solving can be used to identify and implement other improvement opportunities

What you'll be able to do

• Know what is meant by the term standardisation as applied to a business environment
• Know how standardisation can help to make an organisation more competitive
• Know what standard operating procedures are, and their benefits
• Know the areas within a business environment that standard operating procedures seek to address
• Know the key points that are included on a standard operation sheet, and the difference between a ‘main step’ and an ‘operation’
• Know the difference between ‘value added’ and ‘non value added’ activities
• Know the principles of motion economy and how this is incorporated into standard operating procedures
• Collect information for use in preparing a standard operating sheet
• Know the factors that could cause a review of a standard operating procedure
• Know the reasons for having reviews of standard operating procedures
• Know what factors could cause a revision to standard operating procedures

What you'll be able to do

• Define what is meant by ‘visual management’
• Recognise the benefits that can be gained from having visual management systems in place
• Understand how the principles and processes of visual management can be applied in the workplace
• Recognise the different forms of visual management
• Understand to what part of the business different forms of visual management can be applied
• Display information
• Display key business performance measures
• Display key local performance measures
• Understand the improvement actions that will facilitate the deployment of a visual management system
• Understand the measurement techniques that will facilitate the deployment of a visual management system
• Understand how to employ an improvement action that requires a visual management system activity within a work area
• Understand how to prepare and carry out the visual management activity within a chosen work area
• Display and maintain information, using the most appropriate methods
• Display and maintain information, using the most effective methods
• Understand how further improvement actions continue to drive the information and development of the system
• Understand how visual management systems fit in with other lean business activities

What you'll be able to do

• Understand the principal provisions of the Health and Safety at Work Act
• Understand the principal provisions of other current legislation relating to health and safety
• Understand how current legislation affects health and safety issues in respect of employers
• Understand how current legislation affects health and safety issues in respect of employees
• Understand how current legislation affects health and safety issues in respect of the public
• Understand how to obtain information and relevant advice on the organisation's health and safety policy
• Understand the general safe working practices associated with operations in the workplace
• Recognise the types of workplace accidents and emergencies
• Recognise the causes of workplace accidents and emergencies
• Understand the consequences of workplace accidents and emergencies
• Understand the procedures to be followed in the event of accidents
• Understand the procedures to be followed in the event of injuries
• Understand the procedures to be followed in the event of the evacuation of the premises
• Understand the procedures to be followed in the event of dangerous occurrences or hazardous malfunctions
• Understand the hazards and risks associated with work activities
• Understand the importance of being involved in the risk assessment procedure
• Carry out a risk assessment activity
• Understand the steps necessary to minimise the risk of injury or damage when moving a load
• Correctly and safely move a load using the appropriate methods
• Correctly and safely move a load using the appropriate techniques
• Understand how to apply good housekeeping and safe working practices as a basis for the safe implementation of lean business activities