Level 2 Certificate in Lean Organisation Management Techniques Unit 2: Business improvement tools and techniques Assessment You should use this file to complete your Assessment. The first thing you need to do is save a copy of this document, either onto your computer or a USB drive Then work through your Assessment, remembering to save your work regularly When you’ve finished, print out a copy to keep for reference Then, go to www.vision2learn.com and send your completed Assessment to your tutor via your My Study area – make sure it is clearly marked with your name, the course title and the Unit and Assessment number. Please note that this Assessment document has 11 pages and is made up of 4 Sections. Name: Section 1: Continuous improvement techniques [LO1] This section will help you to evidence Learning Outcome 1: Know about continuous improvement techniques (Kaizen). Learning objective 1.1 Identify the main Kaizen principles and their application Place in Assessment Question 1, Page 1 Question 2, Page 2,3,4,5 1. What are the four main Kaizen principles? Identify each one below. [1.1] 1 Continuous Improvement: A company philosophy to keen improving the process in an organization reducing the waste. 2 People: If information flows between the staff, client and suppliers the employees could make decision without the need of a manager. 3 Change: Implementing small but continuous changes is good and the company should promote this mentality to improve the organization. 4 Eliminating waste: Reduce the amount of non-adding value activities to reduce the risk and increase the efficiency © Copyright Creating Careers Ltd, 2015. All rights reserved. 1 Level 2 Certificate in Lean Organisation Management Techniques Unit 2: Business improvement tools and techniques 2. Read the case study below. Case study A toaster manufacturer, ‘Spring Morning’, is experiencing a decline in profits as a result of the struggling economy. The business can’t control the economy but they can look at their own operations and attempt to be as responsible and as lean as possible to prepare for an uncertain future. Read the bullet points below to learn more about how ‘Spring Morning’ operates: ‘Spring Morning’ has been an active business for 4 years and has continued to manufacture its toasters in the same way, using the same raw materials. Many staff have left the company during this time, citing their main reason for leaving as feeling undervalued by management. Another issue amongst staff is the lack of training being made available. Equally, the management has issues with staff. Certain teams within the business are showing a poor attitude to work. One team in particular are causing problems for management due to their refusal to work flexible working hours. Many people have been at the company since it was created and are stubbornly refusing to change their shift patterns. The management is also experiencing difficulties with younger members of staff who have messy work stations and are lacking professionalism in the workplace as a result of this. The office secretary continually takes long breaks. The business has introduced one noticeable change despite its apparent reliance on traditional methods. This year, the company have started using their production plants to create car exhausts, with new production teams entering toaster production plants. An important issue to be addressed is the over production of toasters. In the struggling economy statistics suggest that the toaster market is shrinking rather than growing at the current time. Table Complete the table below to show how Kaizen techniques can make ‘Spring Morning’ a leaner company. Use the bullet points listed below to help structure your answer. In your answer you should consider: How Kaizen techniques could be applied to different parts of the business The setting of defined goals Identifying problems in the work area Types of waste How Kaizen techniques would benefit the business. [1.1] What problems are identifiable in the work area? -There is not a good relation and bad communication between Operator and Management. -Lack of training -No product and process improvement -Employees don’t stay at the company for long periods © Copyright Creating Careers Ltd, 2015. All rights reserved. 2 Level 2 Certificate in Lean Organisation Management Techniques Unit 2: Business improvement tools and techniques -Lack of Leadership in senior people and managers -To introduce a totally different product at the same site using the same methodology -Big manufactured product inventory without hearing the market demand. Identify types of waste within the company. -Big inventory of raw material and finished products. -Over production of the finished material. © Copyright Creating Careers Ltd, 2015. All rights reserved. 3 Level 2 Certificate in Lean Organisation Management Techniques Unit 2: Business improvement tools and techniques How could Kaizen techniques be applied to different parts of the business? Kaizen techniques could help to the company in different ways. The company must hear employees needs and suggestions of how to improve the productivity and where are the bottleneck. For this a better communication between management and operator need to be implemented. The company need to follow the continuous improvement philosophy and make operator participate on this methodology to feel part of the company and make clear that the company hears them. Making small changes in the organization will generate a better understanding of where the non-added value operation and waste are. Improving the efficiency of the company. What goals should be set to make the business leaner? -Improve the communication and relation within operators and manager -Implement and continuous improvement and change methodology -Eliminate the overproduction and reduce the inventory becoming a just in time organization. -Offer trainings to the employees to improve their skill and knowledge of the production lines - Managers should hear employee’s enquiries and make clear which are the changes to be implemented to satisfy both companies and stuff © Copyright Creating Careers Ltd, 2015. All rights reserved. 4 Level 2 Certificate in Lean Organisation Management Techniques Unit 2: Business improvement tools and techniques needs. How could Kaizen techniques benefit the business? © Copyright Creating Careers Ltd, 2015. All rights reserved. 5 Level 2 Certificate in Lean Organisation Management Techniques Unit 2: Business improvement tools and techniques Now that you have completed Section 1 of your Assessment, remember to save the work you have done so far – you will need to send your work to your tutor for marking once you have completed all 4 sections of this Assessment. © Copyright Creating Careers Ltd, 2015. All rights reserved. 6 Level 2 Certificate in Lean Organisation Management Techniques Unit 2: Business improvement tools and techniques Section 2: Principles and techniques of workplace organisation [LO2] This section will help you to evidence Learning Outcome 2: Understand the principles and techniques of workplace organisation. Learning objective Place in Assessment 2.1 Explain areas of weakness in workplace organisation and suggest improvements Question 1, Page 6 1. Using the table below, explain possible areas of weakness in the workplace outlined in the scenario and suggest any improvements that could be made. Your answer should reference each of the 5S or 5C improvements areas. [2.1] Scenario In the last 12 months Patna Publishing, a local publishing company, has experienced rapid growth. However, as they are still based out of their original office, such growth has brought with it a number of issues. To support the company’s expansion they have had to take on 15 new members of staff but space issues have meant that teams are often split up or scattered across the office. Also, new computer equipment has been purchased for all new members of staff which has caused software incompatibility issues with the older computers used by current employees. The office itself lacks a dedicated stationery and storage cupboard which means items of stationery, along with order and invoice forms, are stored haphazardly in different cupboards and boxes are scattered all over the place. Finally, in the past little effort has been made to train employees about desk organisation and cleanliness, meaning many work stations are dusty and cluttered with old paperwork. 5S/5C improvement areas Areas of weakness © Copyright Creating Careers Ltd, 2015. All rights reserved. Suggestions for improvement 7 Level 2 Certificate in Lean Organisation Management Techniques Unit 2: Business improvement tools and techniques Now that you have completed Section 2 of your Assessment, remember to save the work you have done so far – you will need to send your work to your tutor for marking once you have completed all 4 sections of this Assessment. © Copyright Creating Careers Ltd, 2015. All rights reserved. 8 Level 2 Certificate in Lean Organisation Management Techniques Unit 2: Business improvement tools and techniques Section 3: Use visual indicators to improve the work environment [LO3] This section will help you to evidence Learning Outcome 3: Be able to use visual indicators to improve the work environment. Learning objective 3.1 Identify elements that contribute to good visual management in the workplace 3.2 Prepare appropriate visual indicators Place in Assessment Question 1, Page 8 Question 2, Page 8, 9 1. Identify elements that contribute to good visual management for each of the following stages. [3.1] Preparing to implement visual management techniques (VMT) Implementing VMTs Utilising VMTs 2. Prepare appropriate visual indicators for one of the scenarios below. Complete the table below explaining how you would go about doing this. Your answer should include which materials could be used, examples of possible visual indicators and why your chosen visual indicators are appropriate. [3.2] Scenario A Workers in the canteen of a large office building must carry out hygiene checks three times a day – once in the morning, once at lunch and once in the afternoon. To ensure this is done properly, staff are looking to implement a visual system that clearly displays to others whether these checks have been carried out or not. © Copyright Creating Careers Ltd, 2015. All rights reserved. 9 Level 2 Certificate in Lean Organisation Management Techniques Unit 2: Business improvement tools and techniques Scenario B In the print room of an office, there is a wide selection of different paper sizes available that run out at different times. To help the office manager know when to order more paper of a specific size it has been decided that there will be a new VMT introduced so that they can tell at-a-glance when paper is about to run out. Scenario C New recycling bins have been implemented at a local supermarket however the visual displays have proved unclear and confusing to customers, causing waste to be placed in the incorrect bin. As a result, new visual indicators are being developed that are clearer and easier to follow. Scenario: Which materials could be used Examples of possible visual indicators Why chosen visual indicators are appropriate Now that you have completed Section 3 of your Assessment, remember to save the work you have done so far – you will need to send your work to your tutor for marking once you have completed all 4 sections of this Assessment. © Copyright Creating Careers Ltd, 2015. All rights reserved. 10 Level 2 Certificate in Lean Organisation Management Techniques Unit 2: Business improvement tools and techniques Section 4: Eliminate variance from processes in the workplace [LO4] This section will help you to evidence Learning Outcome 4: Know ways to eliminate variance from processes in the workplace. Learning objective 4.1 Describe the benefits of standard working methods Place in Assessment Question 1, Page 10 4.2 Prepare a standardised work document suggesting how to eliminate variance to process Question 2, Page 10, 11 1. Describe the benefits of standard working methods. [4.1] 2. Using the table below, prepare a standardised work document that suggests ways to eliminate variance for a chosen process where you work. Alternatively, choose one of the following processes: [4.2] - Safe preparation of food at a fast food restaurant Operating a supply lift in a supermarket Locking up an office for the weekend Your standardised work document should include factors such as: - Types of material used Description of the process (inputs/outputs) How work flows Layout of the area People involved Kind of actions that occur Time taken Any tools used. Work process document Name: © Copyright Creating Careers Ltd, 2015. All rights reserved. 11 Level 2 Certificate in Lean Organisation Management Techniques Unit 2: Business improvement tools and techniques Work process: Step no. Step Tools used Notes Time Total Now that you have completed Section 4 of your Assessment, remember to save the work you have done so far – you will need to send your work to your tutor for marking once you have completed all 4 sections of this Assessment. © Copyright Creating Careers Ltd, 2015. All rights reserved. 12
