ETCAL
Level 2
QN: 601/5526/7
Curriculum Active
ETCAL Level 2 Certificate In Business Improvement Techniques
Official qualification regulated by Ofqual, awarded by ETCAL. Classified as a Vocationally-Related Qualification. Total guided learning hours: 228 hours.
Qualification Level
Level 2
Awarding Body
ETCAL
Syllabus Units
13 Units
Guided Hours
228 hrs
Instant access to interactive lessons, quizzes, and spaced revision.
Course Syllabus & Study Modules
Complete breakdown of verified curriculum topics and learning objectives.
1
Carrying out autonomous maintenance
Verified
Key Learning Objectives:
- Know the principles of Total Productive Maintenance (TPM)
- Know the ways TPM can help improve the profitability of a business
- Know the ‘5 pillars’ of TPM, and who needs to be involved in its implementation
- Know what preparation is required prior to a TPM activity taking place
- Know the health and safety requirements for the area, and the resources required for a TPM activity
- Be able to apply the practical steps of TPM
- Know the 6 major losses, their impact on a business, and how they can be eliminated
- Be able to collect the information needed to calculate Overall Equipment Effectiveness (OEE)
- Know why it is necessary to audit TPM activities, and the techniques used
- Be able to carry out a TPM audit
- Know what aspects of business performance can improve as a result of TPM
- Know how TPM fits in with other lean business principles
2
Carrying out flow process analysis
Verified
Key Learning Objectives:
- Know the principles of Flow Process Analysis, its benefits and use in a lean manufacturing environment
- Be able to establish ‘value added’ and ‘non value added’ activities
- Know how Flow Process Analysis is applied to a part or process to help identify where waste or problem conditions occur
- Be able to construct a flow analysis sheet to map the process
- Know how to carry out a Flow Process Analysis on a chosen part, using appropriate tools and techniques
- Know how to produce a visual representation of a process using appropriate mapping techniques
- Know the type of improvements that can be made to the process, with defined, quantifiable objectives and targets
- Know the implementation issues that can arise as a result of proposed improvements
- Know how to produce a payback matrix or efficiency statement that prioritises and evaluates improvement opportunities
- Know how Flow Process Analysis fits in with other lean business processes
3
Carrying out set-up reduction techniques
Verified
Key Learning Objectives:
- Know the principles of ‘Set up reduction techniques’, and how it can improve business efficiency and profitability
- Know how to critically evaluate the changes that have been made, or are being proposed, to the set up activity
- Know the role and application of standard operating procedures in sustaining improvements
- Know how effective process set up and changeover techniques can build effective team working in the workplace
- Know how effective process set up and changeover techniques fits in with other lean business principles
- Know why a machine, process or operation can be selected for the improvement activity, and what range of improvements can be possible
- Know the difference between motion and work, and what is meant by value adding and non value adding activities
- Be able to carry out the basic steps in a set up procedure
- Know the basic steps to be followed in a set up procedure aimed at streamlining the set up operation
- Know the preparation needed to be done prior to a set up reduction activity taking place
- Be able to apply the practical steps of ‘set up reduction techniques’ using the ‘Single Minute Exchange of Dies’ (SMED) technique
- Know how to apply effective problem solving methods and techniques to further improve the set up activity
- Know how to set quantifiable targets and objectives for the improvement activity, and how they can be achieved
4
Contributing to the application of kanban control systems
Verified
Key Learning Objectives:
- Know when to use kanbans as part of a stock control, or a production control system
- Know the development of work flow, from traditional push, through visual pull to continuous flow systems
- Know the various types of visual triggers that are used as a means of visual communication
- Be able to create stock control triggers
- Know how kanbans communicate the need for action
- Be able to design and use a two bin system where the container acts as a trigger
- Know how to use multiple containers to cope with high volumes or complex supply chains
- Know how kanbans are important parts of pull systems
- Know how to use input and output kanbans to create flow through a production area or series of processes
- Know the strengths and weaknesses of kanban systems
5
Contributing to carrying out lead time analysis
Verified
Key Learning Objectives:
- Know what lead time is, and how it is used as an improvement tool in a lean business environment
- Know how to identify the representative parts or processes that are suitable for the production of a lead time profile
- Know the type of information required to compile a draft outline of lead time profiles
- Be able to create a lead time profile and frequency diagram for the part or processes that have been analysed
- Know how to fully analyse the current practice in order to identify potential improvements
- Know the type of improvements that can be made to reduce lead time, with defined, quantifiable, objectives, and targets
- Know the implementation issues that can arise as a result of proposed improvements to achieve a targeted lead time
- Know how to plan the improvements needed, and the consequences for the business of not being able to achieve the benefits
- Know how Lead Time Analysis fits in with other lean business activities
6
Contributing to effective team working
Verified
Key Learning Objectives:
- Know the different types of team roles, and how they contribute to effective team working
- Know how working relationships need to extend across appropriate work groups and departments
- Be able to identify individual strengths and weaknesses, and how they contribute to the effectiveness
- Know how individuals behaviour and appearance may be perceived by others
- Know the importance of creating and maintaining effective working relationships
- Know the types of problems and difficulties that can occur within team working relationships, and how they can be resolved
- Know the importance of sharing knowledge, information, and performance measures within the team
- Know how to present information in an amicable and constructive manner, in relation to the team or individual circumstance
- Be able to use different types of communication methods, in order to keep others informed
- Know how to identify the mixture of skills and experience available within a team
- Know how the mixture of skills and experience within a team, contributes to effective team working
7
Contributing to the analysis and selection of parts for improvement
Verified
Key Learning Objectives:
- Know how to identify the selection of parts for improvement from within a chosen area or product range
- Know the type of information required to select representative parts within a chosen area or product range
- Know how to group identified parts into appropriate part families
- Be able to group parts based on part shape, part size, the material used to manufacture the part, and the manufacturing process
- Be able to carry out an analysis
- Know the principles and process of carrying out an analysis
- Know the difference between ‘lead time’ and ‘cycle time’
- Know what is meant by the term ‘bill of materials’ for each of the representative parts
- Know the importance of analysing and selecting parts for improvement
- Know how the analysis and selection of parts for improvement fits in with other lean business techniques
8
Contributing to the Application of Continuous Improvement Techniques _Kaizen_
Verified
Key Learning Objectives:
- Know the importance and need to continuously improve productivity in the working environment
- Know the types of improvement that can be made as part of continuous improvement
- Know what is meant by the term ‘waste’ in business, and how it affects productivity
- Be able to contribute to the elimination of ‘waste’ in a workplace
- Know what benchmarking is
- Know the potential benefits of benchmarking
- Know how to identify the type of improvements that can be made in the workplace
- Know the ‘12’ steps to carrying out a continuous improvement activity
- Be able to carry out a continuous improvement activity
- Know the key performance indicators that are used to measure improvements
- Know how performance indicators are applied, and the results visually communicated
- Know the role of standard operating procedures in sustaining improvements
- Know the importance of an appropriate environment for improvement
9
Contributing to the application of problem solving techniques
Verified
Key Learning Objectives:
- Know the types of problems that can affect a business, and the effects of unresolved problems on business performance
- Know the benefits of adopting a structured approach to problem solving
- Know the techniques available to help identify, contain, and re
- solve problems in the workplace
- Be able to apply the appropriate problem solving technique to identify the root ca
- use of a problem
- Know how the appropriate corrective actions are determined, selected, and implemented to re
- solve problems
- Know the tools and techniques available to prevent the recurrence of a problem
- Know how to capture improvement opportunities, and the actions needed to carry out the improvement effectively
- Know how effective problem recognition and problem solving can be used to identify and implement other improvement opportunities
10
Contributing to the Application of Workplace Organisation Techniques
Verified
Key Learning Objectives:
- Know what a work environment is, and what is meant by an organised working environment
- Be able to identify the benefits that can be achieved by having an organised working environment
- Know the methods and techniques for workplace organisation, and how they are used
- Know how the steps of workplace organisation are implemented
- Be able to apply the first three steps of workplace organisation
- Know the fourth and fifth steps of workplace organisation in order to sustain and improve the workplace
- Be able to carry out a tagging exercise
- Know how to redeploy or dispose of non-essential items from the workplace
- Know why it is necessary to audit workplace organisation activities, and the tools and techniques that are used
- Be able to carry out a workplace organisation audit
- Know how aspects of health, safety, and team work may improve as a result of good workplace organisation
- Know how workplace organisation fits in with other lean business techniques
11
Contributing to the creation of standard operating procedures _SOP_
Verified
Key Learning Objectives:
- Know what is meant by the term standardisation as applied to a business environment
- Know how standardisation can help to make an organisation more competitive
- Know what standard operating procedures are, and their benefits
- Know the areas within a business environment that standard operating procedures seek to address
- Know the key points that are included on a standard operation sheet, and the difference between a ‘main step’ and an ‘operation’
- Know the difference between ‘value added’ and ‘non value added’ activities
- Know the principles of motion economy and how this is incorporated into standard operating procedures
- Be able to collect information for use in preparing a standard operating sheet
- Know the factors that could ca
- use a review of a standard operating procedure
- Know the reasons for having reviews of standard operating procedures
- Know what factors could ca
- use a revision to standard operating procedures
12
Contributing to the development of visual management systems
Verified
Key Learning Objectives:
- Know what is meant by ‘visual management’, and the benefits that can be gained from having visual management systems in place
- Know how the principles and processes of visual management can be applied in the workplace
- Know the different forms of visual management, and to what part of the business they can be applied
- Be able to display information, and key business and local performance measures
- Know the improvement actions and measurement techniques that will facilitate the deployment of a visual management system
- Know how to employ an improvement action that requires a visual management system activity within a work area
- Know how to prepare and carry out the visual management activity within a chosen work area
- Be able to display and maintain information, using the most appropriate and effective methods
- Know how further improvement actions continue to drive the information and development of the system
- Know how visual management systems fit in with other lean business activities
13
Statutory Regulations and Organisational Safety Requirements
Verified
Key Learning Objectives:
- Know the principal provisions of the Health and Safety at Work Act and other current legislation
- Know how current legislation affects health and safety issues in respect of employers, employees and the public
- Know how to obtain information and relevant advice on the organisations health and safety policy
- Know the general safe working practices associated with operations in the workplace
- Know the types, causes, and consequences of workplace accidents and emergencies
- Know the procedures to be followed in the event of accidents, injuries, the evacuation of the premises, and dangerous occurrences or hazardous malfunctions
- Know the hazards and risks associated with work activities and the importance of being involved in the risk assessment procedure
- Be able to carry out a risk assessment activity
- Know the steps necessary to minimise the risk of injury or damage when moving a load
- Be able to correctly and safely move a load using the appropriate methods and techniques
- Know how to apply good housekeeping and safe working practices as a basis for the safe implementation of lean business activities
Regulatory & Verification Details
- Qualification Number (QN)
- 601/5526/7
- Regulated Status
- Available to learners
- Awarding Body
- ETCAL
- Qualification Type
- Vocationally-Related Qualification
- Operational Start
- Feb 2015