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Anne Mette McAloone amc@eanord.dk

A Practical Example of Facilitated Work Based Learning (FWBL) from a Danish Company Implementing LEAN. Anne Mette McAloone amc@eanord.dk. Motivation & background. Adult Vocational Training Programme Arbejdsmarkedsuddannelse (AMU) Teaching in industry Specialised to the company needs

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Anne Mette McAloone amc@eanord.dk

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  1. A Practical Example of Facilitated Work Based Learning (FWBL) from a Danish Company Implementing LEAN Anne Mette McAloone amc@eanord.dk Peder Oxes Allé 4 Tlf. (+45) 48 225 300 info@eanord.dk 3400 Hillerød Fax (+45) 48 225 335 www.eanord.dk Denmark

  2. 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 info@eanord.dk 3400 Hillerød Fax (+45) 48 225 335 www.eanord.dk Denmark

  3. 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 info@eanord.dk 3400 Hillerød Fax (+45) 48 225 335 www.eanord.dk Denmark

  4. 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 info@eanord.dk 3400 Hillerød Fax (+45) 48 225 335 www.eanord.dk Denmark

  5. 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 info@eanord.dk 3400 Hillerød Fax (+45) 48 225 335 www.eanord.dk Denmark

  6. The LEAN strategy • 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 Peder Oxes Allé 4 Tlf. (+45) 48 225 300 info@eanord.dk 3400 Hillerød Fax (+45) 48 225 335 www.eanord.dk Denmark

  7. The LEAN steps 5 Kunde integration • • Produktion i takt 4 Træk system • • Kontrol af kunde lagre • • Hyppige 3 Fleksibilitet leveringer • • Kanban Kanban • Nul fejl • • Andon Andon – – stop stop 2 Stabilitet system system og støt • • Volumen ændringer • • Lagerstyring • • TPM and SMED TPM and SMED 1 Orden • • Fleksibilitet over- for volumen ændringer • • Standardiseret arbejde • • Arbejdsplads & 5S – • • Poka Poka Yoke Yoke • • Organisation, roller og ansvar • VSM • • Problemløsning • Målstyring & Kaizen 1/5 2005 - 1/5 2006 20/3 2006 – 1/7 2007 Peder Oxes Allé 4 Tlf. (+45) 48 225 300 info@eanord.dk 3400 Hillerød Fax (+45) 48 225 335 www.eanord.dk Denmark

  8. 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 info@eanord.dk 3400 Hillerød Fax (+45) 48 225 335 www.eanord.dk Denmark

  9. 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 info@eanord.dk 3400 Hillerød Fax (+45) 48 225 335 www.eanord.dk Denmark

  10. 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 info@eanord.dk 3400 Hillerød Fax (+45) 48 225 335 www.eanord.dk Denmark

  11. 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 info@eanord.dk 3400 Hillerød Fax (+45) 48 225 335 www.eanord.dk Denmark

  12. 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 info@eanord.dk 3400 Hillerød Fax (+45) 48 225 335 www.eanord.dk Denmark

  13. LEAN CD-ROM contents Peder Oxes Allé 4 Tlf. (+45) 48 225 300 info@eanord.dk 3400 Hillerød Fax (+45) 48 225 335 www.eanord.dk Denmark

  14. 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 info@eanord.dk 3400 Hillerød Fax (+45) 48 225 335 www.eanord.dk Denmark

  15. Interviews and cases Peder Oxes Allé 4 Tlf. (+45) 48 225 300 info@eanord.dk 3400 Hillerød Fax (+45) 48 225 335 www.eanord.dk Denmark

  16. The Value Stream Mapping lecture Peder Oxes Allé 4 Tlf. (+45) 48 225 300 info@eanord.dk 3400 Hillerød Fax (+45) 48 225 335 www.eanord.dk Denmark

  17. 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 info@eanord.dk 3400 Hillerød Fax (+45) 48 225 335 www.eanord.dk Denmark

  18. 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 Peder Oxes Allé 4 Tlf. (+45) 48 225 300 info@eanord.dk 3400 Hillerød Fax (+45) 48 225 335 www.eanord.dk Denmark

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