Industrial Systems Technology - FAME Advanced Manufacturing

This course introduces the Federation of Advanced Manufacturing Education (FAME) MCE-1 (Manufacturing Core Exercise) for Safety Culture.  The course includes an introduction to safety and safety practice and the development of a safety culture.  Specific topics covered regarding safety culture are:

1. Internal, self-driven value for safe behavior
2. Active concern for both personal safety and the safety of others
3. Full understanding of the impact and consequence of unsafe behavior and acts
4. Proactive thinking about safety, safe practices, and consequences
5. Self-driven initiative to be safe and to promote the safety of others

This course introduces the Federation of Advanced Manufacturing Education (FAME) MCE-2 (Manufacturing Core Exercise) for Workplace Visual Organization (AKA:  5S).  Students will learn how to achieve higher productivity, produce fewer defects, meet deadlines, attain higher workplace safety, and how to expose abnormal work conditions quickly and easily for correction and countermeasure.  The 5S process will be clearly defined with experiential exercises, reinforcing the following process steps and their objectives: 

1. Sift - Organization
2. Sort - Orderliness
3. Sweep and Wash - Cleanliness
4. Spic and Span - Total Standardization
5. Sustain - System Sustainment

This course introduces the Federation of Advanced Manufacturing Education (FAME) MCE-3 (Manufacturing Core Exercise) for Lean Manufacturing.  Students will be introduced to a systematic method for waste minimization (AKA:  Muda) within a manufacturing system, without sacrificing productivity.  Lean also takes into account waste created through overburden (AKA:  Muri) and waste created through unevenness in workloads (AKA:  Mura).  The Lean management philosophy will be clearly defined and explained with experiential exercises, reinforcing the following concepts:

1. The value-added product
2. The maintenance value-added product
3. Value-added work and necessary work
4. How this leads to increased profit
5. Workload unevenness (Mura)
6. Waste created through overburden (Muri)
7. The seven areas of non-value-added waste (Muda):  conveyance, correction, motion, over-production, over-processing, waiting and inventory

This course introduces the Federation of Advanced Manufacturing Education (FAME) MCE-4 (Manufacturing Core Exercise) for Problem Solving.  Students will learn how to use the eight-step problem-solving model in an experiential learning environment, in conjunction with the PDCA cycle (plan, do, check, and act).  The eight steps students will learn to use are:

1. Clarify the problem (plan)
2. Breakdown the problem (plan)
3. Set the target (plan)
4. Analyze the root cause (plan)
5. Develop countermeasures (plan)
6. Implement countermeasures (do)
7. Monitor results and process (check)
8. Standardize and share success (act)

This course introduces the Federation of Advanced Manufacturing Education (FAME) MCE-5 (Manufacturing Core Exercise) for machine reliability.  Students will learn how to use the process of Reliability-Centered Maintenance (RCM) to drive for zero downtime and reach for maximum Heijunka.  Students will be given an in depth understanding of Heijunka (Japanese for “leveling”), as a process that maintains a balanced relationship between predictability by leveling demand, flexibility by decreasing changeover time and stability by averaging production volume and type, over the long-term.  The RCM process will be clearly defined with experiential exercises reinforcing comprehension and application of the following core questions:

1. What are the functions of the equipment?
2. How does it fail?
3. What causes it to fail?
4. Does it matter if it fails?
5. What can be done to predict or prevent each failure?
6. What if the failure cannot be prevented?