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Anne Mette McAloone 24 th May 2007 Slide 1/18 Peder Oxes Allé 4Tlf. (+45) 48 225 300 3400 HillerødFax (+45) 48 225 335 Denmark.

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Presentation on theme: "Anne Mette McAloone 24 th May 2007 Slide 1/18 Peder Oxes Allé 4Tlf. (+45) 48 225 300 3400 HillerødFax (+45) 48 225 335 Denmark."— Presentation transcript:

1 Anne Mette McAloone 24 th May 2007 Slide 1/18 Peder Oxes Allé 4Tlf. (+45) HillerødFax (+45) Denmark A Practical Example of Facilitated Work Based Learning (FWBL) from a Danish Company Implementing LEAN Anne Mette McAloone

2 Anne Mette McAloone 24 th May 2007 Slide 2/18 Peder Oxes Allé 4Tlf. (+45) HillerødFax (+45) Denmark 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

3 Anne Mette McAloone 24 th May 2007 Slide 3/18 Peder Oxes Allé 4Tlf. (+45) HillerødFax (+45) Denmark 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

4 Anne Mette McAloone 24 th May 2007 Slide 4/18 Peder Oxes Allé 4Tlf. (+45) HillerødFax (+45) Denmark 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

5 Anne Mette McAloone 24 th May 2007 Slide 5/18 Peder Oxes Allé 4Tlf. (+45) HillerødFax (+45) Denmark The target employees Machine operators Blacksmiths Engineering dept. Production planning Laboratory Quality dept. Technicians VSM courses Poka Yoke courses

6 Anne Mette McAloone 24 th May 2007 Slide 6/18 Peder Oxes Allé 4Tlf. (+45) HillerødFax (+45) Denmark 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

7 Anne Mette McAloone 24 th May 2007 Slide 7/18 Peder Oxes Allé 4Tlf. (+45) HillerødFax (+45) Denmark 1 Orden Arbejdsplads & 5S– Organisation, roller og ansvar Problemløsning Målstyring & Kaizen 2 Stabilitet TPM and SMED Standardiseret arbejde PokaYoke TPM and SMED PokaYoke 3 Fleksibilitet Andon–stop og støt Lagerstyring Fleksibilitet over- for volumen ændringer Andon–stop 4 Træk system Hyppige leveringer Kanban system Volumen ændringer Kanban system 5 Kunde integration Produktion i takt Kontrol af kunde lagre Nul fejl VSM 1/ / / – 1/ The LEAN steps

8 Anne Mette McAloone 24 th May 2007 Slide 8/18 Peder Oxes Allé 4Tlf. (+45) HillerødFax (+45) Denmark 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

9 Anne Mette McAloone 24 th May 2007 Slide 9/18 Peder Oxes Allé 4Tlf. (+45) HillerødFax (+45) Denmark 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

10 Anne Mette McAloone 24 th May 2007 Slide 10/18 Peder Oxes Allé 4Tlf. (+45) HillerødFax (+45) Denmark 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

11 Anne Mette McAloone 24 th May 2007 Slide 11/18 Peder Oxes Allé 4Tlf. (+45) HillerødFax (+45) Denmark 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 DKK

12 Anne Mette McAloone 24 th May 2007 Slide 12/18 Peder Oxes Allé 4Tlf. (+45) HillerødFax (+45) Denmark 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

13 Anne Mette McAloone 24 th May 2007 Slide 13/18 Peder Oxes Allé 4Tlf. (+45) HillerødFax (+45) Denmark LEAN CD-ROM contents

14 Anne Mette McAloone 24 th May 2007 Slide 14/18 Peder Oxes Allé 4Tlf. (+45) HillerødFax (+45) Denmark 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

15 Anne Mette McAloone 24 th May 2007 Slide 15/18 Peder Oxes Allé 4Tlf. (+45) HillerødFax (+45) Denmark Interviews and cases

16 Anne Mette McAloone 24 th May 2007 Slide 16/18 Peder Oxes Allé 4Tlf. (+45) HillerødFax (+45) Denmark The Value Stream Mapping lecture

17 Anne Mette McAloone 24 th May 2007 Slide 17/18 Peder Oxes Allé 4Tlf. (+45) HillerødFax (+45) Denmark 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

18 Anne Mette McAloone 24 th May 2007 Slide 18/18 Peder Oxes Allé 4Tlf. (+45) HillerødFax (+45) Denmark Please take your own copy of the LEAN CD-ROM Learn more about LEAN Get stories and hints from two Danish companies working with LEAN Try the quiz Teach yourself VSM


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