NVQ in Business Improvement Techniques

Centre Guide to changes to www.cityandguilds.comJanuary 2008

the National Occupational Standards Version 1.0

Contents

Introduction 3

Scope 3

Unit 1 Complying with Statutory Regulations and Organisational Safety requirements 4

Unit 2 Contributing to Effective team Working 5

Unit 3 Leading Effective Teams 6

Unit 4 Applying workplace organisation 7

Unit 5 Applying Continuous Improvement Techniques (Kaizen) 9

Unit 6 Creating Flexible Production and Manpower Systems 11

Unit 9 Creating Visual Management Systems 12

Unit 10 Carrying out Value Stream Mapping (VSM) 13

Unit 11 Applying Set-up Reduction Techniques (SMED – Single Minute Exchange of Dies) 14

Unit 12 Applying Total Productive Maintenance (TPM) 15

Unit 13 Applying Problem Solving Techniques 16

Unit 15 Applying Flow Process Analysis 17

Unit 29 Carry out Mistake/Error Proofing (Poka Yoke) 18

Unit 35 Carrying out Project Management Activities 19

Unit 36 Creating Standard Operating Procedures 20

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Introduction

This document is designed to help Centres already running with Business-Improvement Techniques to determine the changes that have been made by the Science, Engineering and Manufacturing Technologies Alliance (SEMTA) to the National Occupational Standards (NOS). This document is designed to supplement the revised Handbook which is also available via the City and Guilds website.

Scope

NVQs for Business-Improvement Techniques are work-based qualifications designed for those employed within engineering, manufacturing, processing and other related industries.

The revised NOS became effective as of 01.01.2008. Fifteen units within the Business-Improvement Techniques award have had their standards revised. This document covers those units.

Each unit incorporates a:

• Unit Summary • Performance Statement • Scope of Unit • Knowledge Statement

To help Centres identify what changes have been made the following terms have been used:

• No change – only used under one of the above headings where no changes have been made.

• Added – used where a word/sentence has been added to a sentence/paragraph/bullet point/statement.

• Replaces – used where a word/sentence has been replaced in a sentence/paragraph/bullet point/statement.

• Deleted – used where a word/sentence/bullet point/statement has been deleted. • New – used where a new bullet point or statement has been added. This will not indicate

what the new bullet point or statement is (please refer to the Handbook for this information).

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Unit 1 Complying with Statutory Regulations and Organisational Safety requirements

Unit Summary The last sentence (last paragraph) ‘improvement’ has been added. Performance statements No change. Scope of the unit No change. Knowledge statements These have been increased from 16 to 17.

Statement 1: added ‘and other current legislation (such as The Management of Health and Safety at Work Regulations, Workplace Health and Safety and Welfare Regulations, Personal Protective Equipment at Work Regulations, Manual Handling Operations Regulations, Provision and Use of Work Equipment Regulations, Display Screen at Work Regulations, Reporting of Injuries, Diseases and Dangerous Occurrences Regulations.’ Statement 5: added ‘working in confined spaces’ Statement 6: deleted ‘such as hazard spotting & safety inspections, the use of hazard check lists, carrying out risk assessments, COSHH assessments and safe systems of working. Statement 8: New

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Unit 2 Contributing to Effective team Working

Unit Summary Second sentence (first paragraph) added ‘whilst challenging fixed ideas’. Performance statements No change. Scope of the unit 3 Communicate in writing and /or electronically to include three from the following:

Bullet point 5: new

Knowledge statements These have increased from 16 to 18 Statement 5: new Statement 6: new

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Unit 3 Leading Effective Teams

Unit Summary No change. Performance statements: No change. Scope of the unit No change. Knowledge statements Statement 9: Added ‘workplace organisation’

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Unit 4 Applying workplace organisation

Unit Summary Paragraph 1 only. ‘a systematic approach to continuously make improvements to the workplace organisation’ replaces ‘the principles of workplace organisation in a continuous improvement environment’. ‘(such as 5S or 5C)’ replaces ‘to your work area and establishing an area score.’ ‘materials’ and ‘or require a new location’ added to third sentence. ‘improve the condition of the working environment’ replaces ‘increase the area 5S/5C score where this is possible.’ Also deleted is the paragraph on the origin of the 5S’s from Japanese words. Performance statements Statement 3: ‘resources or’ replaces ‘tools and’ & ‘or in surplus and where improvements can be made’ replaces ‘and where improvements can be made to increase the area 5S/5C score.’ Statement 5: replaces ‘increase the area 5S/5C score’. Scope of the unit 1 Produce and/or contribute to the identification of improvements in existing standard

operating procedures which cover three of the following:

Bullet point 1: added: ‘/work area’ Bullet point 5: added: ‘/working processes’ Bullet point 6: ‘systems’ replaces ‘operations’ Bullet point 7: new

2 Produce and/or contribute to the production of visual controls, which cover three of the

following:

Bullet point 1: added: ‘or an alternative (such a labelled racking and storage systems)’ & ‘resources and/or’ Bullet point 2: deleted ‘of equipment’ Bullet point 3: added ‘(such as line, process system)’ Bullet point 7: new Bullet point 8: new

Knowledge statements These have been reduced from 12 to 11. Statement 2: ‘an activity’ replaces ‘a 5S/5C activity’. Statement 3: replaces ‘what is a red tag exercise and how it is carried out’ Deleted Statement (was 4): ‘how to conduct a 5S/5C auction within a given timescale’

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Statement 6: replaces ‘the principles and process for deployment of 5S/5C’. Statement 7: replaces ‘how to score and audit for the deployment of 5S/5C’. Statement 9: added ‘such as information sheets, boards or’

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Unit 5 Applying Continuous Improvement Techniques (Kaizen)

Unit Summary To last sentence (first paragraph) added ‘improved customer service’. Performance statements These have increased from 9 to 11. Statement 7: new Statement 8: added ‘or other approved documentation that will sustain’ Statement 9: new Scope of the unit 1 Identify improvements within the working area/activity which cover three of the following:

Bullet point 1: replaces ‘reduced product cost’ Bullet point 2: replaces ‘improved safety’ Bullet point 4: new Bullet point 7: added ‘and/or energy usage’

Bullet point 8: new Bullet point 9: new

2 Produce and/or contribute to the identification and application of improvements, which

cover three of the following

Bullet point 1: added ‘or work area’ Bullet point 5: added ‘or work area operations’ Bullet point 6: ‘system’ replaces ‘improvements’ Bullet point 7: new

3 Determine and calculate one of the following quality measures:

Bullet point 1: added ‘as a percentage or as’ 4 Determine and calculate one of the following measures:

Bullet point 2: added ‘or service’

5 Determine and calculate one of the following cost measures:

Bullet point 2: new Bullet point 7: added ‘energy’

6 Record and show business improvement using one of the following key performance

indicators:

Bullet point 1: added ‘as a percentage or as’ Bullet point 6: new Bullet point 11: added ‘energy’

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Knowledge statements: These have increased from 16 to 20 Statement 4: added ‘human’ Statement 10: replaces ‘why you must not blame the people who have identified the potential improvement. Statement 15: ‘business’s’ replaces ‘DTI’. Also added ‘such as the DTI’s seven measures’ Statement 16: new Statement 17: new Statement 18: new Statement 19: new

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Unit 6 Creating Flexible Production and Manpower Systems

Unit Summary In the first sentence (first paragraph) ‘business’ replaces ‘production and manpower.’ Performance statements Statement 3: added ‘or materials’ Scope of the unit 1 Choose three different parts or materials in the work area and calculate the following:

‘or materials’ added to above. 2 Produce a visual communication of the schedule which includes:

‘level’ deleted from above. 3 Create a visually controlled system based on the demand of subsequent processes for the

chosen parts or materials which include four of the following:

‘or materials’ added to above Bullet point 3: added ‘or material’

Knowledge statements Statement 11: added ‘material’ Statement 18: replaces ‘how to lay out a workplace utilising cellular manufacturing techniques (parallel lines or u shaped cells).’

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Unit 9 Creating Visual Management Systems

Unit Summary No change. Performance statements No change. Scope of the unit 1 Create and update visual management systems that promotes six of the following:

Bullet point 1: added ‘health and’ Bullet point 2: added ‘quality/’ Bullet point 9: added ‘/material’ Bullet point 13: new Bullet point 14: new

Knowledge statements No change.

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Unit 10 Carrying out Value Stream Mapping (VSM)

Unit Summary In the last sentence of the first paragraph ‘reduced waste’ has been added. Also in the second paragraph ‘or material’ has been added on three occasions. Performance statements Statement 2: added ‘or materials’

Statement 4: added ‘or materials’

Scope of the unit 1 Identify opportunities for improvements and waste that needs to be removed in order to

create a future state map covering three of the following:

Bullet point 5: new Bullet point 6: new Bullet point 7: new

2 Produce current and future State Maps which include the following:

Bullet point 1: added ‘or material’ Bullet point 5: added ‘or material’

Knowledge statements No change.

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Unit 11 Applying Set-up Reduction Techniques (SMED – Single Minute Exchange of Dies)

Unit Summary The following have been added to the second sentence (first paragraph): ‘change over, clean down or turnaround’ and ‘such as capacity, flexibility, lead time, inventory or other business performance measure.’ In the first sentence (second paragraph) ‘and/or contribute to improving’ has been deleted. Performance statements Statement 2: ‘productivity’ replaces ‘process capacity’

Statement 7: replaces ‘produce and/or update existing Standard Operating Procedures (SOP’s) which meet the new set-up requirements. Scope of the unit

1 Make improvements to the current set-up which cover three of the following:

Bullet point 5: new Bullet point 6: new

2 Produce and/or contribute to the identification and application of improvements to the new

set-up, which covers three of the following: See above - ‘and application of improvements to the new set-up’ replaces ‘of improvements to existing standard operating procedures for the new set up’

Bullet point 5: new Bullet point 6: new

Knowledge statements Statement 9: added ‘or update’ and ‘or other approved documentation’

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Unit 12 Applying Total Productive Maintenance (TPM)

Unit Summary In the second sentence (first paragraph) ‘the six classic’ has been added. In the first sentence (second paragraph) ‘condition based’ has been added. Performance statements No change. Scope of the unit

3 Collect information relating to:

Bullet point 1: added ‘or demand’ Bullet point 3: added ‘or bottleneck analysis’

Knowledge statements Statement 2: ‘principles of TPM’ replaces ‘five classic TPM principles’ Statement 4: ‘How to implement a systematic and structured approach to carrying out’ replaces ‘how to carry out the seven steps of’

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Unit 13 Applying Problem Solving Techniques

Unit Summary In the last sentence (first paragraph) ‘improved output, health and safety and regulatory compliance’ has been added. Performance statements No change. Scope of the unit 1 Participate in problem solving activities, taking on one of the following key roles:

Bullet point 4: new

2 Identify the savings within the chosen problem solving activity covering two of the following:

Bullet point 3: added ‘or service’

Bullet point 5: new Bullet point 6: new Knowledge statements Statement 5: replaces ‘How to establish a problem profile and the involvement of the customer in the problem solving issues’

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Unit 15 Applying Flow Process Analysis

Unit Summary No change. Performance statements No change. Scope of the unit No change. Knowledge statements Statement 3: ‘working’ replaces ‘manufacturing’ Statement 5: ‘or deployment flowchart using the recognised symbols (such as defined in ASME) on a flow process sheet’ replaces ‘using the ASME symbols on a flow process sheet’

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Unit 29 Carry out Mistake/Error Proofing (Poka Yoke)

Unit Summary No change. Performance statements No change. Scope of the unit 1 Identify the benefits of mistake/error proofing in terms of:

Bullet point 1: added ‘/compliance (such as ISO9001 and Good Manufacturing Practice, GMP)’ Bullet point 3: added ‘or service’

Knowledge statements Statement 13: ‘workplace organisation 5S/5C, quick changeovers, cellular manufacturing, Total Productive Maintenance’ replaces ‘continuous improvement processes such as’

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Unit 35 Carrying out Project Management Activities

Unit Summary No change. Performance statements Statement 4: ‘personnel’ replaces ‘subject and technical experts’ Scope of the unit

3 Monitor the progress of the project to ensure:

Bullet point 1: new Bullet point 2: ‘delivered’ replaces ‘delivery’

Knowledge statements Statement 4: deleted ‘such as MS Project and Gantt charts.’

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Unit 36 Creating Standard Operating Procedures

Unit summary No change. Performance statements Statement 3: ‘will meet quality, productivity, health, safety and environmental requirements’ replaces ‘achieves quality and productivity requirements’ Scope of the unit: 1 Produce three Standard Operating Procedures from of the following:

Bullet point 3: added ‘and environmental’

2 Produce Standard Operating Procedures that include all of the following:

Bullet point 2: added ‘/product’ (twice)

Knowledge statements Statement 2: added ‘activities’ Statement 15: ‘action’ replaces ‘schemes’

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