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Peder Oxes Allé 4 Tlf. (+45) 48 225 300 [email protected] Hillerød Fax (+45) 48 225 335 www.eanord.dk Denmark
Anne Mette McAloone
24th May 2007Slide 1/18
A Practical Example of Facilitated Work Based Learning (FWBL) from a Danish Company Implementing LEAN
Anne Mette [email protected]
Peder Oxes Allé 4 Tlf. (+45) 48 225 300 [email protected] Hillerød Fax (+45) 48 225 335 www.eanord.dk Denmark
Anne Mette McAloone
24th May 2007Slide 2/18
Motivation & background
• Adult Vocational Training Programme– Arbejdsmarkedsuddannelse (AMU)
• Teaching in industry • Specialised to the company needs• Long-term relation with the company• Course-on-demand
Peder Oxes Allé 4 Tlf. (+45) 48 225 300 [email protected] Hillerød Fax (+45) 48 225 335 www.eanord.dk Denmark
Anne Mette McAloone
24th May 2007Slide 3/18
Disposition
• Motivation & background• An example of FWBL:
– The company, its employees and the LEAN strategy
– The courses and structure– The benefits of the training– Off-courses learning
• The LEAN CD-ROM– Contents and uses
Peder Oxes Allé 4 Tlf. (+45) 48 225 300 [email protected] Hillerød Fax (+45) 48 225 335 www.eanord.dk Denmark
Anne Mette McAloone
24th May 2007Slide 4/18
The company
• Haldor Topsøe A/S• Located in Frederikssund• Production in 8 divisions• Process industry – produce catalysts• Approx. 550 employees on site• Implementing LEAN since 2005• Successful integration of training and LEAN• Close relation to the LEAN consultant; Lasse
Veng
Peder Oxes Allé 4 Tlf. (+45) 48 225 300 [email protected] Hillerød Fax (+45) 48 225 335 www.eanord.dk Denmark
Anne Mette McAloone
24th May 2007Slide 5/18
The target employees
• Machine operators• Blacksmiths• Engineering dept.• Production planning• Laboratory• Quality dept.• Technicians
VSM
courses Poka Yoke
courses
Peder Oxes Allé 4 Tlf. (+45) 48 225 300 [email protected] Hillerød Fax (+45) 48 225 335 www.eanord.dk Denmark
Anne Mette McAloone
24th May 2007Slide 6/18
• Focus on training employees the LEAN principles
• Periodic training for current and new employees
• Ensure that all employees receive exactly the same training
• Use e-learning, as a supplement to traditional training
• Support by the management
The LEAN strategy
Peder Oxes Allé 4 Tlf. (+45) 48 225 300 [email protected] Hillerød Fax (+45) 48 225 335 www.eanord.dk Denmark
Anne Mette McAloone
24th May 2007Slide 7/18
1 Orden
•Arbejdsplads & 5S–• Organisation, roller
og ansvar• Problemløsning
••
•Målstyring & Kaizen
2 Stabilitet
• TPM and SMED•Standardiseret
arbejde• Poka Yoke
• TPM and SMED•
• PokaYoke
3 Fleksibilitet
• Andon – stop og støt
• Lagerstyring•Fleksibilitet over-
for volumen ændringer
• Andon – stop
••
4 Træk system
• Hyppige leveringer
• Kanbansystem
• Volumen ændringer
•
• Kanbansystem
•
5 Kunde integration
• Produktion i takt
• Kontrol af kundelagre
Nul fejl
•
•
•
•
• VSM
1/5 2005 - 1/5 2006 20/3 2006 – 1/7 2007
The LEAN steps
Peder Oxes Allé 4 Tlf. (+45) 48 225 300 [email protected] Hillerød Fax (+45) 48 225 335 www.eanord.dk Denmark
Anne Mette McAloone
24th May 2007Slide 8/18
The LEAN courses
• Spring 2006– LEAN introduction & Value Stream Mapping (VSM)– 18 courses over 1 year – 3 days course– 300 employees directly related to production and 50 in
admin
• Spring 2007– Problem solving & Poka Yoke– 15 courses over 6 months – 2 days course– 280 employees directly related to production and 20 in
admin
• Autumn 2007– Process control & statistics– Planning of the courses in progress
Peder Oxes Allé 4 Tlf. (+45) 48 225 300 [email protected] Hillerød Fax (+45) 48 225 335 www.eanord.dk Denmark
Anne Mette McAloone
24th May 2007Slide 9/18
The course structure
• Theoretical knowledge• Practical training/exercises• Discussion (between divisions)• Group work (project & teams)• On the job/off the job - project (1-4
weeks)• Project presentation (managers present)• Exam, course evaluation and certificate
Peder Oxes Allé 4 Tlf. (+45) 48 225 300 [email protected] Hillerød Fax (+45) 48 225 335 www.eanord.dk Denmark
Anne Mette McAloone
24th May 2007Slide 10/18
The benefits
• Learning through doing the work– The learning process begins after the course,
which is the most interesting process of learning
• Problem solving in own areas– It is relevant and makes a difference!
• Obtaining and using production information– Forcing employees to seek production data and
costs
Peder Oxes Allé 4 Tlf. (+45) 48 225 300 [email protected] Hillerød Fax (+45) 48 225 335 www.eanord.dk Denmark
Anne Mette McAloone
24th May 2007Slide 11/18
And what it is worth
• Each course delivers 3-4 improvement projects and generate many more ideas
• Implementing LEAN and working with continuous improvement saves money
• Employees enter the LEAN management • Some of the projects has a potential cost
reduction/saving of more than 800.000 DKK
Peder Oxes Allé 4 Tlf. (+45) 48 225 300 [email protected] Hillerød Fax (+45) 48 225 335 www.eanord.dk Denmark
Anne Mette McAloone
24th May 2007Slide 12/18
Developing the LEAN CD-ROM
• e-learning material for teaching – “The future industrial worker”– “The future office worker”– Supported by The European Social Fund
• Alternative to LMS (Moodle) platform• Portrait companies working with LEAN• Teaching in a specific LEAN tool - VSM
Peder Oxes Allé 4 Tlf. (+45) 48 225 300 [email protected] Hillerød Fax (+45) 48 225 335 www.eanord.dk Denmark
Anne Mette McAloone
24th May 2007Slide 13/18
LEAN CD-ROM contents
Peder Oxes Allé 4 Tlf. (+45) 48 225 300 [email protected] Hillerød Fax (+45) 48 225 335 www.eanord.dk Denmark
Anne Mette McAloone
24th May 2007Slide 14/18
Supplement to training
• For new employees• Refresh knowledge• Present to managers• Use in LEAN events/workshops• Use as a dictionary and assist
in project work
Peder Oxes Allé 4 Tlf. (+45) 48 225 300 [email protected] Hillerød Fax (+45) 48 225 335 www.eanord.dk Denmark
Anne Mette McAloone
24th May 2007Slide 15/18
Interviews and cases
Peder Oxes Allé 4 Tlf. (+45) 48 225 300 [email protected] Hillerød Fax (+45) 48 225 335 www.eanord.dk Denmark
Anne Mette McAloone
24th May 2007Slide 16/18
The Value Stream Mapping lecture
Peder Oxes Allé 4 Tlf. (+45) 48 225 300 [email protected] Hillerød Fax (+45) 48 225 335 www.eanord.dk Denmark
Anne Mette McAloone
24th May 2007Slide 17/18
Conclusion
• The workplace is turned into a learning place
• Communicate the company strategy and goals into the training material
• Include company specific knowledge and information in the course
• Evaluation of course and current needs
Peder Oxes Allé 4 Tlf. (+45) 48 225 300 [email protected] Hillerød Fax (+45) 48 225 335 www.eanord.dk Denmark
Anne Mette McAloone
24th May 2007Slide 18/18
Please take your own copy of the LEAN CD-ROM• Learn more about LEAN• Get stories and hints
from two Danishcompanies workingwith LEAN
• Try the quiz• Teach yourself VSM