Skills Portfolio 2010

CONTENTS

NVQ Training:
 Business Improvement Techniques Level 2
 Business Improvement Techniques Level 3
 Lean Office Level 2
 Performing Manufacturing Operations Plus Level 2
 Performing Engineering Operations Level 2
 Warehousing & Storage Plus Level 2
 Business & Administration Level 2
 Customer Service Level 2
 Information Technology Qualification Level 2
 Team Leader

Apprenticeships:
 Customer Service
 Business & Administration
 Information Technology Qualification
 Performing Manufacturing Operations
 Performing Engineering Operations
 Warehousing & Storage

Rapid Improvement Workshops:
 5S & Workplace Organisation – 1 day
 Kaizen & Continuous Improvement – 1 day
 FMEA (Failure Mode Effect Analysis – 1 day
 Introduction to Lean – 1 day
 The Lean Leader Programme (Level 3)
 Management to Leadership

Case Studies / Testimonials

Programme Information

Business Improvement Benefits:

Techniques (BIT) • Proven productivity
improvement model

• Phased and structured approach
“Productivity”, “Lean Thinking”, “Continuous Improvement”
and “Waste” - all these terms are synonymous with the • Accredited against a
national standard
Manufacturing and Engineering sector.
• Deliver improved
The reality is that manufacturing organisations have workforce capability
struggled for decades in a highly competitive environment • Increases “can do” and
to reduce defects and waste whilst battling to create “know how”
optimum flow by using Lean principles. With more
pressure on companies than ever before, these tools • Sustainable through champions
are now being adopted on a wider scale. The Public • Quantified monetary savings
and Service sectors are using them increasingly to help are created as part of the
reduce costs, whilst ultimately achieving more value BIT programme
for their customers.

The BIT that counts

BIT explores the concept of continuous improvement
and demonstrates how eliminating waste, reducing
variation and preventing defects can dramatically
improve business performance. From the Japanese
5S method to the Kaizen approach, the programme
covers the most up-to-date management thinking.
Delivered at your workplace, the programme sees
your employees implementing improvement projects
on your shop floor.

We have successfully rolled out this programme in
the Manufacturing, Engineering, Public and Service
sectors, so are uniquely aware of its application for all.

/// We also offer programmes in Management Development /// Visit www.businessimpactuk.com to find out more ///

Programme Framework

NVQ Diploma in Business Improvement
Techniques Level 2

Induction enrolment:
Covering completion of ILP,
literacy and numeracy
assessments, BIUK policies
and procedures. Equality
and Diversity and
Safeguarding also Improvement activity 1
introduced. 2.5 hours. Shop floor application session.
8 hours.

UPK 1: Covering, 5S Improvement activity 2
workplace organisation, Shop floor application session.
Health and Safety, Visual 8 hours
Management, and Team
working. 4 hours.

Improvement activity 3
Shop floor application session.
8 hours.
UPK 2: Covering, Kaizen,
Health and Safety, Team
working, Problem Solving,
Data collection and analysis.
4 hours.

UPK 3: Covering, Health and
Safety, Kaizen, Problem
Solving, Data collection and
Analysis. 4 hours.


Business Improvement
Techniques (BIT) Level 3 • Reduce costs, variation
and waste

• Improve business performance

Following on from level 2, this Business Improvement Techniques • Maximise pro ts and revenues
.
quali cation at level 3 is designed for managers, supervisors and
other sta who have an important role to play in the business. • Helps reduce workplace
The quali cation enables these individuals to develop the skills accidents
they need to be able to act as continuous improvement facilitators • Achieve results with minimal
within the organisation and lead improvement projects. disruption to operations

The quali cation includes training in the following areas: • Improved sta morale

Leading E ective Teams
Applying Problem Solving Techniques
Creating and Maintaining Standard Operating Procedures

Plus an additional unit from the following to be selected in line
with company needs:

Flow Process Analysis
SMED (a waste reduction tool to assist rapid changeover)
TPM (Total Productive Maintenance)

The training is followed by three facilitated improvement project
days where the team utilise the methods they have learned during
the training to create and analyse process maps, identify suitable
improvement projects on the shop oor and implement those
improvements.

/// Management Development /// Visit www.businessimpactuk.com to out more ///

BIT LEVEL 3 PROCESS FLOW

UPK 1. 8 Hours.
Leading Teams,
P/Solving, SMED
techniques.

UPK 2. 4-8 Hours.
SMED techniques
continued and
SOPs.

Facilitated
Improvement
Session 1.
Individuals to lead a
5’S activity and close
out actions from
Improvement 1.

Facilitated
Improvement
Session 2.
5’S activity and close
out actions from
Improvement 2.
Facilitated
Improvement
Session 3.
5’S activity and
close out actions
from Improvement
3.
Follow up and
close out session.


Lean Office Benefits to the employers:

• Improved business performance
While many organisations have successfully applied to assist in winning contracts
the principles of Lean Manufacturing to the factory floor,
often companies overlook the benefits that streamlining • Reduction in costs and waste
administrative functions can deliver to the bottom line… • Increased profits and revenues
and to customer service.
• Reduction in workplace accidents
Typically some 60% – 80% of all costs related to a product • Improved staff morale
are non-production costs, but due to lack of understanding and performance
in the identification and monitoring of value-add in non-
manufacturing (identifying value is a crucial first step on
the road to improvement), businesses fail to address many
important issues. By focusing on the end-to-end process
it can become clear that, despite making significant
improvements in the process, often the overall lead-time
has improved very little.

The Business Improvement Techniques (NVQ) qualification
is designed to assist organisations in improving their
business activities by applying the tools and techniques
of continuous improvement. Business Impact have adapted
this hugely successful qualification and adjusted the focus
to reflect the back office and administrative support
functions to address areas such as:

1. Workplace Organisation
2. The identification and elimination of waste
3. Operational effectiveness
4. Teamwork and communication
5. Improvement and productivity

This programme is designed to ensure that all activities
add value and are sustainable, impacting on Quality,
Cost and Delivery performance that:

• Eliminates the risk of a poor service reaching the customer
• Reduces operational costs
• Improves profitability and competitiveness

/// We also offer programmes in Management Development /// Visit www.businessimpactuk.com to find out more ///

Programme Framework:

Lean Office Level 2

Induction / Enrolment – The Lean Office
Qualification
Individual Learning Plan (ILP)
Numeracy & Literacy Assessment
Analysis of Training Needs
Introduction to the Lean Office Qualification

UPK Session 1 – Health & Safety + Teamwork
HASAWA 1974
Health & Safety in the Office
Manual Handling and COSHH
Risk Assessment
Teamwork and Team Roles

UPK Session 2 – Workplace Organisation
The Working Environment
Structured Workplace Organisation
Auditing the Work Area
Visual Management Systems
Workplace Visual Management Opportunities

UPK Session 3 – Continuous Improvement
Continuous Improvement
Work and Waste (The Eight Wastes)
Analysing the Work Process
Key Performance Indicators (KPI’s)
Matching Work Level to Customer Demand

UPK Session 4 – Problem Solving & Standardisation
of Work
Cause & Effect Analysis
Identifying Underlying Causes
Selecting Solutions
Standard Work Practises
Office Ergonomics

Improvement Activity x 3 – Quality, Cost & Delivery
Area Risk Assessment
Workplace Organisation Audit (Pre & Post)
Data Gathering and Problem Definition
Underlying Cause Identification
Solution Generation
Improvement Proposal
Record of Area Status before Improvement
Improvement Implementation
Record of Area Status after Improvement
Improvement Close Out & Action Plan


Performing Manufacturing Benefits:

Operations Plus (PMO Plus)  Buy into best methods of
working from employees and
maybe a starting point for a
learning journey

The Performing Manufacturing Operations NVQ Level 2 is  Opportunity to participate in
primarily for confirming the competence of existing employees a 5S work based
and for ensuring standardised working/audit compliance. improvement project
Confirmation of competence is Assessed via a series of on the
Costs:
job observations by a Business Impact Assessor and carried out
on normal shift patterns at the place of work. For this  Time off the job
qualification it is essential that staff can perform manufacturing
operations and would normally do so on a daily basis.  Fully funded qualification for
1st Level 2 and partially
By observing and having dialogue the Assessor captures written funded for 2nd Level 2
evidence for example: wearing the correct PPE and awareness
of the H&S requirements; housekeeping is in order; knows what
to do if a non-conformance could or has occurred; good
understanding of the process and any variables. At the end of
each observation the Assessor will share the written feedback
with your employee and they have the opportunity to amend and
review along with the Team Leader. Any necessary actions are
agreed prior to the next observation.

Employees will also participate in a half day 5S work based
improvement project for their area.
Time off the job: 2 hour enrolment session/induction, then 3 on
the job observations/assessments each with a 20 minute
review. 4 hours for the improvement project.

Considerations: maximum group size of 12 for the enrolment
session; short refresher training as part of induction?


PERFORMING MANUFACTURING
OPERATIONS NVQ L2 PROGRAMME

Enrolment/Induction Option for Training
2 hours Session: 5S & basic audit
Group size c.12 improvement
2-4 hours

1st on the job assessment
& observation
Includes 20 minute 1:1 &
agreed actions for next
observation

2nd on the job assessment
and observation
agreed actions for the next
observation

3rd on the job assessment
and observation
Includes 20 minute 1:1 to
confirm all actions have
been completed

Certification
of Achievement


Performing Engineering Benefits:

Operations  Allows individuals the
opportunity to gain skills and
recognition in the area in
which they work

 Ensures your organisation
The Performing Engineering Operations NVQ Level 2 is has competent personnel
primarily for confirming the competence of existing employees who can perform skills to
and for ensuring standardised working/audit compliance. industry standards
Confirmation of competence is assessed via a series of on the
job observations by a Business Impact Assessor and carried out
on normal shift patterns at the place of work. For this Costs:
qualification it is essential that staff can perform engineering
 Time off the job
operations and would normally do so on a daily basis.
 Fully funded qualification for
By observing and having dialogue the Assessor captures written 1st Level 2 and partially
evidence for example: wearing the correct PPE and awareness funded for 2nd Level 2
of the H&S requirements; housekeeping is in order and knows
what to do if a non-conformance could or has occurred; At the
end of each observation the Assessor will share the written
feedback with your employee and they have the opportunity to
amend and review along with the Team Leader. Any necessary
actions are agreed prior to the next observation.

review.

session.


PERFORMING ENGINEERING
1st on the job assessment
Enrolment/Induction & observation
2 hours Includes 20 minute 1:1 &
Group size c.12 agreed actions for next
observation

Option for Training
Session: observationaudit
and 5S & basic
improvement
2-4 hours
observation

and observation
been completed

Professional Discussion
with candidate and review
of product evidence

Witness testimony taken Certificate of
from candidates’ line achievement
manager to confirm
competence


Warehousing & Storage Plus Benefits:

(WAS Plus)  Buy into best methods of
working from employees and
The Warehousing & Storage NVQ Level 2 is primarily for maybe a starting point for a
learning journey
confirming the competence of existing employees and for
ensuring standardised working/audit compliance. Confirmation  Opportunity to participate in
of competence is Assessed via a series of on the job a 5S work based
observations by a Business Impact Assessor and carried out on improvement project
normal shift patterns at the place of work. For this qualification
it is essential that employees perform a full cycle of activity from Costs:
orders to picking/packing to dispatch.
 Time off the job
By observing and having dialogue the Assessor captures written
evidence for example: wearing the correct PPE and awareness  Fully funded qualification for
of the H&S requirements particularly in relation to Fork Lift 1st Level 2 and partially
funded for 2nd Level 2
Trucks, stacking etc.; housekeeping is in order; knows what to
do if a non-conformance could or has occurred; good
understanding of the process and any variables. At the end of
each observation the Assessor will share the written feedback
with your employee and they have the opportunity to amend and
review along with the Team Leader. Any necessary actions are

Employees will also participate in a half day 5S work based
improvement project for their area.

review. 4 hours for the improvement project.

session; short refresher training as part of induction?


WAREHOUSING & STORAGE
Enrolment/Induction Option for Training
2 hours Session: 5S & basic audit
Group size c.12 improvement
2-4 hours

1st on the job assessment &
observation
agreed actions for next
observation

and observation
observation

and observation
been completed

Certification
of Achievement


Business and Administration Benefits:

The Business and Administration NVQ Level 2 is primarily for
confirming the competence of existing employees and for  Improved time management
ensuring standardised working/audit compliance. Confirmation
of competence is assessed via a series of on the job  Increased productivity
observations by a Business Impact Assessor and carried out on
normal shift patterns at the place of work. For this qualification  A reduction in administrative
errors
it is essential that staff can perform administrative duties and
would normally do so on a daily basis.
Costs:

By observing and having dialogue the assessor captures written  Time off the job
evidence, for example: health and safety, working effectively
with others, producing documents, processing customer  Fully funded qualification for
transactions and researching and reporting information.. At the 1st Level 2 and partially funded
end of each observation the assessor will share the written for 2nd Level 2
feedback with your employee and they have the opportunity to
amend and review, along with the Team Leader. Any
necessary actions are agreed prior to the next observation.

the job observations/assessments each with a 20 minute review


Customer Service Benefits:

 Consistent delivery of
customer service excellence
The Customer Service NVQ Level 2 is primarily for confirming within your organisation
the competence of existing employees and for ensuring
 Customer queries are dealt
standardised working/audit compliance. Confirmation of with quickly and resolved
competence is assessed via a series of on the job observations effectively
by a Business Impact Assessor and carried out on normal shift
patterns at the place of work. For this qualification it is essential Costs:
that staff can perform customer service duties and would
normally do so on a daily basis.  Time off the job

By observing and having dialogue the assessor captures written  Fully funded qualification for
evidence, for example: communicating with customers, 1st Level 2 and partially
promoting additional services or products, processing customer funded for 2nd Level 2
service information, delivering customer service excellence and
dealing with customer queries effectively. At the end of each
observation the assessor will share the written feedback with
your employee and they have the opportunity to amend and
review, along with the Team Leader. Any necessary actions are

the job observations/assessments each with a 20 minute review


Information Technology Benefits:

Qualification  Evaluating the impact of ICT

 Developing new tools and
The ITQ NVQ Level 2 is primarily for confirming the competence techniques
of existing employees and for ensuring standardised
working/audit compliance. Confirmation of competence is Costs:
assessed via a series of on the job observations by a Business
Impact Assessor and carried out on normal shift patterns at the  Time off the job
place of work. For this qualification it is essential that staff can
perform ICT functions and do so, on a daily basis.  Fully funded qualification for
1st Level 2 and partially
By observing and having dialogue the Assessor captures written funded for 2nd Level 2.
evidence for example: Using IT systems, using IT to exchange
information, word processing and the use of database software.
At the end of each observation the Assessor will share the
written feedback with your employee and they have the
opportunity to amend and review along with the Team Leader.
Any necessary actions are agreed prior to the next observation.

review.


Introductory Award Team Leading
in Team Leading NVQ Level 2
The introductory award in team leading is designed as a The Level 2 NVQ in Team Leading is designed for
starting point for aspiring team leaders or those who are team leaders who are primarily concerned with motivating
new to a team leading role. The programme gives learners their team members and achieving agreed outputs, with
a basic knowledge of the various roles, functions and limited authority for deploying resources. Flexibility is
responsibilities of a team leader. achieved through optional units, which complement the
four mandatory units designed to develop the core
competences needed by today’s team leaders.

Certificate in
Team Leading
The Level 2 Certificate in Team Leading programme
comprehensively covers the full range of responsibilities
of the team/group leader or member, and can be tailored
to fit your specific needs. The certificate develops leaders
and managers within the national qualifications framework.

The full Certificate consists of an induction, four 15-hour
modules plus tutorial support. The modular route reinforces
the commitment to short, sharp, flexible learning to
ensure an exact fit with individual candidate needs and
workplace requirements.

/// We also offer programmes in Workforce Development /// Visit www.businessimpactuk.com to find out more ///


Customer Service Framework:

Apprenticeship  9 month programme

 NVQ L2 in Customer Service

 Functional Skills in Maths,
The Apprenticeship Framework: English & ICT

The framework is made up of four elements:  Certificate in Customer
Service
 NVQ L2 in Customer Service
 Functional Skills in Maths, English & ICT  Employment Rights &
Responsibilities
 Certificate in Customer Service
 Employment Rights & Responsibilities Costs:

It is a 9 month programme and all elements must be completed  Fully funded for all learners
in order to achieve an apprenticeship in Customer Service. aged 16-24

The apprenticeship programme is open to anyone, but is only
funded for individuals aged between 16 and 24.

The NVQ:

The NVQ is designed for people who are able to carry out
administrative functions as part of their daily role.

The course includes:
• Giving customers a positive impression of the
organisation
• Promoting additional services or products to customers
• Processing customer service information
• Going “the extra mile” in customer service
• Providing good customer service within the rules
• Living up to the customer service promise

Programme Information Continued

Functional Skills:

GCSE’s are not, in the opinion of employers, giving individuals the
necessary skills required in the work place.

Functional Skills are transferable skills that are valued by employers
and provide a base from which individuals can develop other
employability skills.

They are tools that enable people to:

 Apply their knowledge and understanding in everyday life
 Engage competently and confidently with others
 Solve problems in both familiar and unfamiliar situations

Technical Certificate:

This provides individuals with the underpinning knowledge required to
carry out their role effectively. It contains information on health &
safety and legislation. Knowledge is confirmed through completion of
an on line assessment.

Employment Rights & Responsibilities:

This provides individuals with information about their organisation,
such as, contracts of employment, policies and procedures, equality &
diversity, data protection and general sources of information and
advice.

Assessment & Delivery:

Assessment is conducted by a qualified assessor, with a wealth of
experience and occupational competency in the area of learning.

There are many ways that an individual’s competency can be
assessed and these include:

 Observation
 Product Evidence (naturally occurring in the workplace)
 Questioning
 Guided Discussion

All assessments take place on the job, it is anticipated that a small
amount of down time will be required to complete the functional skills
element of the framework.


Business & Administration Framework:


 NVQ L2 in Business &
Administration

The Apprenticeship Framework:  Functional Skills in Maths &
English
The framework is made up of four elements:
 Award in Administration
 NVQ L2 in Business & Administration
 Functional Skills in Maths & English  Employment Rights &
Responsibilities
 Award in Administration
 Employment Rights & Responsibilities Costs:

It is a 9 month programme and all elements must be completed  Fully funded for all learners
in order to achieve an apprenticeship in Business & aged 16-24
Administration.


The NVQ:

The NVQ is designed for people who are able to carry out
administrative functions as part of their daily role.

• Maintaining a safe working environment
• Working towards the organisations objectives
• Managing customer relations
• Using IT in administration
• Researching and reporting information
• Working effectively with other people


ITQ Apprenticeship Framework:

 9 month programme

The Apprenticeship Framework:  NVQ L2 in ITQ

 Functional Skills in Maths &
The framework is made up of three elements:
English

 NVQ L2 in Information Technology Qualification  Employment Rights &
 Functional Skills in Maths & English Responsibilities
 Employment Rights & Responsibilities
Costs:
It is a 9 month programme and all elements must be completed
in order to achieve an apprenticeship in Information Technology  Fully funded for all learners
aged 16-24
Qualification.


The NVQ:

The NVQ is designed for people who are working in a
manufacturing environment and this can apply to a variety of
disciplines.

• IT troubleshooting
• IT maintenance
• Specialist and bespoke software
• Using IT to exchange information
• E mail
• Spreadsheets


Performing Manufacturing Framework:

Operations Apprenticeship  9 month programme

 NVQ L2 in Performing
Manufacturing Operations

English
 Certificate in Manufacturing
 NVQ L2 in Performing Manufacturing Operations Practices
 Functional Skills in Maths & English
 Employment Rights &
 Certificate in Manufacturing Practises
Responsibilities
Costs:
in order to achieve an apprenticeship in Performing  Fully funded for all learners
Manufacturing Operations. aged 16-24


The NVQ:

The NVQ is designed for people who are working in a
manufacturing environment and this can apply to a variety of
disciplines.

• Health, safety and security in the workplace
• Storage,
• Transferring materials
• Preparing for manufacturing operations
• Complying with statutory regulations and organisational
safety requirements
• Analysing the results if inspection and confirming quality
of production

Activity Plan

Performing Manufacturing
Operations Apprenticeship

Week No. Activity Time Required

1 Induction & Initial Assessment 1 day - off the job

3 Skills Gap Assessment/ERR 1 day - off the job

5 Functional Skills /ERR 1 day - off the job

7 Functional Skills/Technical Certificate 1 day - off the job








23 Observation of Work Practice ½ day – on job assessment



29 Professional Discussion ½ day – on job assessment

30 Portfolio Sign Off ½ day – on job assessment

32 Key Skills Assessments 1 day - off the job

34 Technical Certificate Assessment 1 day - off the job


Performing Engineering Framework:

Operations Apprenticeship  12 month programme

 NVQ L2 in Performing
The Apprenticeship Framework: Engineering Operations

The framework is made up of four elements:  Functional Skills in Maths,
English & ICT
 NVQ L2 in Performing Engineering Operations
 Technical Certificate
 Functional Skills in Maths, English & ICT appropriate to chosen
 Technical Certificate pathway
It is a 12 month programme and all elements must be Responsibilities
completed in order to achieve an apprenticeship in Performing
Engineering Operations. Costs:

 Fully funded for all learners
The apprenticeship programme is open to anyone, but is only aged 16-24

The NVQ:

The NVQ is designed for people working on engineering related
tasks as part of their daily role.

• Working safely in an engineering environment
• Working efficiently and effectively in an engineering
environment
• Using and communicating technical information
• Making components using hand tools and fitting
techniques]

The above list is only a small sample of the units available
and the qualification can be tailored to the operator’s job
role.


Functional Skills:








such as, contracts of employment, policies and procedures, equality &
advice.




 Observation
 Questioning

All assessments take place on the job, it is anticipated that some down
time will be required to complete the functional skills element of the
framework.


Warehousing & Storage Framework:


 NVQ L2 in Warehousing &
Storage

English
 Certificate in Warehousing &
 NVQ L2 in Warehousing & Storage Storage Principles
 Functional Skills in Maths & English
 Certificate in Warehousing & Storage Principles
Responsibilities
Costs:
in order to achieve an apprenticeship in Warehousing &  Fully funded for all learners
Storage. aged 16-24


The NVQ:

The NVQ is designed for people who are involved in either the
movement of goods, hygiene, customer service and stock
control or a combination of these within a warehouse
environment.

 Health, safety and security in the workplace
 Storage
 Processing orders
 Receiving deliveries
 Assembling orders for dispatch
 Dispatching orders
 Working effectively within the organisation


Functional Skills:








such as contracts of employment, policies and procedures, equality &
advice.




 Observation
 Questioning

All assessments take place on the job, it is anticipated that a small
amount of down time will be required to complete the functional skills
element of the framework.

Rapid Improvement Workshops

5s & Workplace Organisation
1 day • Tangible improvements
within your workplace

• Improved sta skill levels

The quality of your working environment can have a big impact • Increased product and process
quality
on the e ciency of your operations. A well organised workplace
with an e cient layout saves time, reduces accidents, increases
• Immediate results
productivity and improves quality.
• Improved health and safety
What is 5s?
5s is often referred to as housekeeping, however the elements of • Decreased down time
5s, and of this workshop, go beyond that. 5s is a philosophy that,
when adopted within an organisation, can signi catnly improve the
e ciency of the organisations activity.

Workshop Content

Unlike most other 5s programmes this 1 day workshop is made up of 20%
theory and 80% application so actual improvements are made to your
workplace.

The theory covered includes:
Origins of 5s
Elements of 5s
Red Tagging
5s Audit Sheets
Sustaining the e ort

A Business Impact Consultant will work with you to identify areas
for improvement within your organisation to ensure that you receive
the best possible bene ts from the workshop.



Kaizen & Continuous Improvement
1 day • Reduced waste

• Improved sta skill levels

Adopting and implementing a Kaizen philosophy is key to ensuring • Cost savings
your business processes are continuously improved to drive down costs
and increase competitiveness through improvements in quality, time spent • Immediate results
on activities.
• Helps create a culture of
The key to adopting this philosophy and ensuring it is as successful as continuous improvement
possible within your organisation is not only ensuring your sta have
an understanding but are also able to implement it within the workplace.

This one day workshop covers both of these elements by developing the
knowledge of your sta and facilitating an improvement project in your
workplace with the group taking part.

Workshop Content

Unlike most other Kaizen programmes this 1 day workshop is made up of 20%
theory and 80% application so actual improvements are made to your
workplace.

Kaizen de nition and teamwork
The PDCA cycle
Check sheets and Pareto analysis
The seven wastes
Identifying waste in a process
Reducing waste in A process




FMEA (Failure Mode and E ects Analysis)

1 day • Improved quality

• Improved customer satisfaction

The ability to improve your business processes is key to ensuring your • Reduced down time
oragnisation drives down costs, improves quality and boosts
productivity. Having people within your organisation with the skills to • Creates emphasis on problem
prevention
be able to identify valuable areas for improvement goes a long way to
achieving this. • Reduced waste

What is FMEA? • Improved sta skill levels
Failure Mode and E ects Analysis is a tool used to identify potential
failure modes within a process, determine their e ect on the
quality of the process and its outcome and identify corrective meaures
to combat those failures which cause the greatest potential risk.

Workshop Content

Unlike most other FMEA programmes this 1 day workshop is made up of 20%
theory and 80% application so actual analysis is carried out in your
workplace.

The concept of FMEA and risk
Design FMEA and process FMEA
Calculating RPN - Severity, Occurence, Detection
The FMEA sheet
Creating an action plan using FMEA




Introduction to Key Outcomes:

Lean Manufacturing Upon successful completion
of this module the participant

1-day programme
will be able to:

1. Describe the principles of Lean
Manufacturing and the benefits
of applying lean concepts across
The Lean concept is basically all about getting the right a business.
things, to the right place, at the right time, in the right
2. Explain the importance of
quantity while minimising time, in the right quantity Standard Operating Procedures
while minimising waste and being open to change - and it
applies to the whole of the organisation from order entry 3. List the stages in the application
to accounts received. It demands effective leadership, of a 5s programme
commitment and engagement of the workforce to create 4. Define the terms value-add
a flexible and responsive organisation. This session and non value-add in a Lean
introduces the fundamental concepts and philosophy Manufacturing environment.
of Lean methodology and allows participants to apply
these in a simple ‘production line’ practical activity.




Lean Manufacturing Upon successful completion of this
module the participant will be able to:

2-day programme 1. Describe the role of value, flow,
pull and waste reduction in a Lean
Manufacturing environment

This 2-day programme provides participants with a practical 2. Explain the importance
introduction to the topic of Lean Manufacturing and also of standardisation
introduces some of the essential tools required to categorise, 3. List the eight Lean KPI’s
monitor and control processes. Through a combination of
classroom sessions, practical activities and workplace audits, 4. Explain the use of Takt
time to match output to
participants experience first-hand the tools, techniques and customer demand
methodologies that today’s manufacturing companies use
to reduce costs and increase productivity. 5. Calculate basic capability
indices (Cp/Cpk)

6. Describe the link between
variation and the
Normal distribution

7. Explain the fundamentals of
Statistical Process Control

8. Select appropriate methods to
arrange and organise ideas as part
of the problem solving process




Lean Manufacturing Upon successful completion of this
module the participant will be able to:

5-day programme 1. Describe the principles of lean
manufacturing and the benefits

Application
of applying lean concepts across
a business.
2. Understand production smoothing,
SMED and how this enables
JIT flexibility.
The Practical Introduction to Lean Manufacturing module
3. Explain the terms, Flow, Pull, Takt,
is designed to provide an understanding of the principles
JIT and Jidoka and how these relate
of Lean Manufacturing and how these principles can be to the strategic implementation of
applied within the workplace. lean manufacturing.
This programme introduces the fundamental concepts and 4. Recognise the key elements
philosophy of Lean methodology and allows participants to and fundamentals of lean
combine these with the essential support tools and techniques manufacturing including
identification and elimination
to ensure effective application.
of waste, visual management,
workplace organisation and
standardisation.
5. Demonstrate the use of Value
Stream Mapping to identify
value added and non-value
added activity.
6. Collect and analyse live data from
a process (selecting the correct
problem solving tool) using Quality,
Cost and Delivery criteria.
7. Apply the principles of cellular
working and workplace
organisation (e.g. 5S and Visual
Management Systems) to improve
the effectiveness, flexibility,
response, quality and safety
of the work area.
8. Identify, categorise (using the seven
wastes model) and prioritise waste
from a process.
9. Develop standardised work plans
to eliminate variation from
the process.
10. Apply effective visual management
to sustain improvements within
the workplace.
11. Apply tools and techniques to
reorganise and evaluate a process
using Lean criteria.
12. Demonstrate an understanding
of the application of Lean principles
and communicate this to others.



The Lean Leader Objectives:

Programme (Level 3) • Provide candidates with appropriate
Lean Leader skills and knowledge
• Support them to apply their
The Lean Leader is a programme of knowledge and knowledge and skills to a live
initiative or Business
skills based on an Institute of Leadership & Management
Improvement programme
qualification that has been enhanced to address the
effective implementation and sustainability of Lean • Enable candidates to measure
business improvements, with
projects in either Manufacturing or Service environments. specific focus on Quality, Cost
and Delivery.
The aim of this programme is to provide tailored leadership
and management skills to Supervisors, Team Leaders,
Managers and Change Agents to maximise the sustainability
of Lean initiatives and business improvement programmes
in both Manufacturing and Service organisations. The course
will provide candidates with appropriate Lean Leader skills
and knowledge, support them to apply these to live Lean
initiatives and business improvement programmes, and
enable them to measure business improvements.



Management to
Leadership
This programme is designed to provide the essential skills
that today’s managers require to implement and drive
productivity improvements within the organisation by
becoming effective leaders.

The programme consists of three topic areas:

• How to lead and be effective
• Utilisation of selected productivity tools and techniques
• Strategies for making change happen

Each participant will understand what they have to do to
improve their leadership skills and they will be helped
to make the necessary adjustments as they learn how to
use selected productivity tools and techniques to improve
the performance of a process.

This programme is unique in achieving immediate
improvements in how the participant impacts their team,
colleagues and customers - while identifying and
eliminating waste and inefficiency in the manufacturing
process. The programme consists of three modules:

1. Leadership for managers
2. Selected productivity tools and techniques
3. Strategies for change and project management


Current clients that we work with........

Case Study – Arla Foods, Palmers Green

We have been working with Arla Foods at their Oakthorpe Site since May 2009 and
so far 30 learners have completed their BIT Level 2. Arla have been extremely
pleased with our progress and the changes he has seen take place onsite since we
started last year. Our contact at Arla foods; the Continuous Improvement Co-
ordinator believes these changes have been a direct result of the programmes we
have delivered there. He has also been fully involved in the programme and is
currently working towards his Level 3 having completed Level 2.

He said the most valuable factor to come out of the training has been to see the
learners engage and start to utilise their new skills after the NVQs have been
completed. This has also been a great help to the company as learners are starting
to be set their personal development plans and continuous improvement is an
objective everyone is being set.

A key improvement that has been made was to put a procedure in place to ensure a
piece of equipment (Cyroscope) no longer needed to be calibrated and parts
replaced every month. This simple improvement has saved Arla over £700 per
month since July 2009; £6,300 so far. Since this projected was completed in the
laboratory, all equipments that are used now have similar care points introduced and
the Cyroscope has not needed to be serviced since July 2009.

In the Cream Department, one of the issues raised was around time being wasted
when labels ran out on the labelling machine. The team looked at different ways of
solving this and came up with an effective use of visual aids and hourly checks to
ensure the labels never ran out. They then attached a Perspex top to the labeller and
when the reel goes into the “red”, the operator, who has to carry out hourly checks
replaces the reel and ensures the line continues to run. This has saved over 2 hours
per day of “downtime” that was caused by labels running out.

The improvement teams also looked at organising labels in the milk filling plant and
organising the engineering materials. This has saved them time when looking for
parts and also ensures that the labels are kept in the correct condition. Due to these
small improvements Arla have also passed inspections by Tesco, Co-op and
Sainsburys.

Case Study – Rolls Royce, Barnoldswick

Thirty six learners formed the first four pilot groups over two sites at Rolls Royce in
Barnoldswick near Burnley. These two sites manufacture all the turbine blades for
Rolls Royce engines worldwide. The first pilot groups have completed and we are
currently enrolling new learners across all sites. The main challenge for us was to
align the Business Improvement Techniques Level 2 qualification against the Rolls
Royce “Process Excellence” journey.

The first pilot group was a mixture of learners; two young apprentices, a doctor, a
black belt, a green belt and the remainder were engineers. Our biggest challenge
with that group was to create differentiation between the learners. They were part of
the transactional team that led them to complete the projects around “Process Flow”
within the internal FPA system. The FPA system is an internal vehicle with which to
authorise change to processes. They successfully reduced NRFT of the FPA
passing at the review board by changing flow process by creating an SOP to control
this. The team created an internal programme to monitor the FPA’s. After that they
looked at how the “Management of Change” (MOC) documentation was affected by
the FPA and how it impacted on lead time. The final project was around parts
awaiting sign off allowing them to go to stores to be sold. All projects that were
implemented were successful and action plans are in place for the team to move
forward.

Another pilot group comprised of shop floor operatives and engineers and they
looked at “blade rework reductions” at the Bankside site and also “improving die-set
turnaround” at the Ghyll Brow site. Initial improvement figures for both groups are
extremely encouraging and again action plans are in place to carry this forward.

Rolls Royce is currently enrolling groups across other sites.

Selex Ltd Testimonials

Being in a supervisory role, the Lean Manufacturing training program has provided me with a
sound basis for the promotion and implementation of successful process improvement ideas.
This in turn leads to the encouragement of all staff members to become involved in further
improvements that they know will achieve results.

Andy Gardner
Production Test Manager
UK Operations

SELEX Communications Ltd has been using the Business Improvement Techniques NVQ
course as a key element of our training strategy for our Operations staff. The course
dovetails very effectively with our lean manufacturing strategy. So far 16 of our people have
achieved NVQ level 2 and this year we plan to put 13 through level 3 training as well as
running another level 2 course. The course has been very popular with the trainees who
have enjoyed the mix of theory and practical hands-on projects many of which have
provided sustained process improvements for our business. In addition, the methodology
advocated by the trainers has become the basis for our own in-house lean improvement
team, formed from the course graduates. Business Impact’s trainers are both
knowledgeable and professional, and I would have no hesitation in recommending this
training scheme.

Andy Forrester
Efficiency Improvement Manager
UK Operations

Camerons Brewery Hartlepool Testimonial

As the brewing industry consolidates within the UK through brewery closures due to the
economic downturn, we have set our stall out to be a contact brewer of major brands. To be
successful within this very competitive arena, we have to be capable of demonstrating to our
prospective and existing clients that we will take the utmost care in producing their valuable
brands to their exact expectations. To meet this need we have invested more than £4 million
in the brewery infrastructure however it does not end there. Camerons’ recognise that the
development of its staff is crucial to ensure that industry best practice is adopted within the
brewery. Through involving Business Impact as our main training provider, we have
embarked on a fundamental organisational development programme that encapsulates the
Lean Manufacturing ethos.

So far 50 employees have gained an NVQ level 2 in Business Improvement Techniques that
has been delivered by Business Impact through a suite of classroom workshops and
workplace applications. I’ve been impressed by the standard of tuition and expertise in
nurturing students along, many of which have not studied in many years.

The next phase of the training programme has commenced with the remaining 50
employees being involved. We have suggested a level 3 course as a follow up and have
been inundated with volunteers.

Well so far what has the course delivered? That of course is best answered by our
customers!

Comments from a customer visit last week:
The improved work standards and communications are also a sign that you are openly
working to a more organised and structured approach. The use of displays for the Lean
audits as well as the work instructions show that these are actively in use with the teams -
and are not just something being discussed in the offices.
It really has been good to track the changes over the last year, but the visual impact of the
tour yesterday really helped enforce the higher standards being implemented.

Billy McKee
Commercial Director
Cameron's Brewery

Guardian Print Centre Manchester Testimonial

Guardian Print Centre (Manchester) has employed Business Impact to implement
the NVQ in Business Improvement Techniques (Level 2). The programme
is currently being delivered to all employees throughout the organisation. Benefits
and improvements have already been realised on a cost, quality and delivery
platform. Attendees have taken part from all departments with the emphasis on
encouraging cross functional team development. The course mixes under pinning
knowledge sessions with real improvement projects so as to create a shop floor
culture of continuous development and improvement.

I can highly recommend Business Impact as a provider of the NVQ programme. As a
training provider, they understand the problems experienced in rolling out such a
programme in a highly skilled manufacturing process environment. They have been
flexible in arranging courses to suit production and also adapting the course to suit
the organisation's requirements. The two trainers used have both been friendly,
approachable, knowledgeable and professional with excellent feedback received
from those who have already passed the course. GPC Manchester is looking forward
to continuing it's partnership with Business Impact as a training provider.

Ade Knott
Line Manager
Guardian Print Centre

General Mills, Berwick upon Tweed Testimonials

“Business Impact staff were useful as a resource, seeing the factory floor with fresh
eyes. Their broad awareness of manufacturing processes and standards has helped
us immensely”

“Business Impact staff were professional, friendly and helpful. They easily
established a rapport with your workforce, integrating in the business and interacting
with our staff very well”

“After company induction for Business Impact staff, very little input was needed from
us”

“Business Impact staff carried out training with minimal disruption to production and
always gave a clear update on progress”

They brought their own paperwork, files etc. so no additional administration was
needed. Working out of the small area, couple of desks, chairs and some storage
space was all they needed. Sometimes we forgot they were Business Impact staff
and not our own!”

“The trainers were flexible in terms of providing BIT overview sessions for Area
Managers and meeting with Hygiene Manager to design new training for next year.
They were always prepared to offer support and share their learning’s with the
business”

Fiona McIntosh, HR Manager
Brian Douglas, Production Manager
General Mills

For further details on how we may assist you further please contact us
directly on 0191 4971920.

Business Impact UK Ltd
(Head Office)
Endurance House
Colmet Court
Seventh Avenue
Team Valley
Gateshead
NE11 0EF
info@businessimpactuk.com

www.businessimpactuk.com

Skills Portfolio 2010

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