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

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]


Anne Mette McAloone


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


Anne Mette McAloone


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


Anne Mette McAloone


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


Anne Mette McAloone


The target employees

• Machine operators• Blacksmiths• Engineering dept.• Production planning• Laboratory• Quality dept.• Technicians

VSM

courses Poka Yoke

courses


Anne Mette McAloone


• 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


Anne Mette McAloone


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


Anne Mette McAloone


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


Anne Mette McAloone


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


Anne Mette McAloone


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


Anne Mette McAloone


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


Anne Mette McAloone


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


Anne Mette McAloone


LEAN CD-ROM contents


Anne Mette McAloone


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


Anne Mette McAloone


Interviews and cases


Anne Mette McAloone


The Value Stream Mapping lecture


Anne Mette McAloone


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


Anne Mette McAloone


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

Documents

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