Todays manufacturing companies have to achieve

operational excellence to succeed in business. This drives the

need to do things faster, better and at reduced cost and
requires a continuous improvement in skills.
The translation of thought leadership into practical action
underpins all of Peras manufacturing offerings. We
understand the challenges facing manufacturing companies
and have a strong track record in developing skills that
enable participants to deliver tangible business
improvements in the workplace.
All of our clients have one thing in common, they want to
develop their skills to deliver rapid operational improvement
in a sustainable manner. The content and style of our
training and the opportunity to interact with people from
other manufacturing companies delivers this.
Our approach to training
Through our practical industry experience and training
know-how, we demystify jargon, integrate practical and
relevant exercises and encourage feedback and full
participation. This makes our programmes highly interactive
and enjoyable. Most importantly, however, our courses focus
on delivering results. In this context we build participants
knowledge and confidence to implement the lessons learnt
and encourage them to identify specific actions that they
will take away as a result of the training. In this way, the
training acts directly as a catalyst as well as a means of
generating improvement.

Free with every course

Your delegates can order
any one of these books
absolutely free for each and
every public manufacturing
skills course that they
attend with Pera.
These book titles have been
selected by our course
leaders as being both
stimulating and practical - a
perfect complement to the
training.

manufacturing skills

Manufacturing skills training excellence in action

New for this year is a series of one day manufacturing

seminars. These key insights will build participants awareness
of cutting edge issues, helping them to see the relevance
and application of these issues to their business.
We are also repeating our successful Lean Manufacturing
programme this year. This series of workshops enables
participants to identify and eliminate waste in the
manufacturing workplace. It is an especially useful
programme when run on an in-house basis as participants
then address issues that are directly relevant to their business
and develop specific action plans that achieve measurable
improvement.
Pera we know how to align knowledge, people and
technology for manufacturing competitive advantage.

Book on www.pera.com or call 01869 340361 or fax 01869 340659

35

manufacturing seminar series

The Manufacturing Seminar Series

NE
W

Last year we regularly received requests for information about key manufacturing topics from people who werent
at the stage of needing training but who wanted to learn more about a topic and its application in their business.
In response we are presenting a new programme of seminars at our Middle Aston House facility. These seminars
are targeted at senior executives and are designed to provide attendees with insights into organisational benefits
and implementation issues.
Lean manufacturing
Lean Manufacturing is a well established approach used by leading practice organisations. It focuses on the
identification and elimination of all forms of waste in the manufacturing process. The approach uses a range of
tools and techniques combined with the development of empowered work teams to deliver impressive operational
results. This seminar will cover:
Seminar outline
What is Lean Manufacturing?
What are the benefits?
An overview of the tools and techniques
How to implement Lean Manufacturing.

Seminar Information
Dates: 21 Jan, 8 Apr, 23 Sept
Cost: 250 Venue: Middle Aston House

Blitz Kaizen
Blitz Kaizen events are a very effective tactical Lean tool for delivering accelerated improvements. Often
companies need to achieve rapid results in response to a specific problem. They also often want to achieve early
tangible success as part of a wider lean implementation. The use of Blitz Kaizen events is a highly effective way
of achieving this. This seminar will cover:
Seminar outline
What is a Blitz Kaizen event and where does it fit in Lean? Seminar Information
Examples and case studies
Dates: 4 Feb, 22 Apr, 7 Oct
Planning for Blitz Kaizens
Cost: 250 Venue: Middle Aston House
Running Blitz Kaizens.

Six Sigma
Six Sigma is gaining a high profile in many leading manufacturing companies. It is a structured, statistically based,
improvement methodology that targets the identification and reduction of variation within the manufacturing
process. Six Sigma is proven to reduce the level of defects and errors and consequently delivers significant bottom
line benefits.
Seminar outline
What is Six Sigma?
What are the benefits?
An overview of Six Sigma tools
How to implement Six Sigma.

Seminar Information
Dates: 18 Feb, 6 May, 21 Oct
Cost: 250 Venue: Middle Aston House

Overall Equipment Effectiveness and Total

Productive Maintenance
A foundation for effective Just-in-Time manufacture is process reliability. TPM is a structured approach to maximise
the non-machine interface by ensuring that processes operate consistently at optimum condition. OEE is the
measure for TPM and can be used to monitor performance and, more importantly, identify areas for improvement.
Seminar outline
The five pillars of TPM
Benefits of TPM
How to calculate OEE
Tips for TPM implementation.

36

Seminar Information
Dates: 20 May, 4 Nov
Cost: 250 Venue: Middle Aston House

All courses can be tailored or run in-house. Call 01869 340361

Waste Elimination and

Value Stream Mapping

The Lean Manufacturing Programme

The identification of waste and the elimination of

non-value adding activities is the foundation of Lean
Manufacturing. This workshop provides the tools
required to capture the various forms of waste and to
implement effective countermeasures.
Course Objectives

Each course in this programme can be attended as a

stand-alone event or grouped together in a logical
sequence to show how the various techniques work
to support one another. The courses are ideal for a
company team based programme in which the
material and presentation is tailored to your specific
needs. A package fee and accredited certificate are
available for attendance of the whole series.
The Lean Manufacturing series is designed to meet a
wide range of attendee expectations. Whether you
are setting up a green-field site or looking to
improve your existing manufacturing practices,
whether you are looking for a practical explanation
of the terminology or looking for proven tips on
shop-floor implementation the Lean Manufacturing
Programme is a must for anyone who is serious
about Manufacturing Improvement.

Understand the essence of Lean Thinking

Build a different and wider perspective on waste
Be able to spot waste within the work environment
Be able to map current and future Value Stream
Maps
Know how to measure waste and monitor the
success of improvement activities
Identify a back at work project plan.

Course Content

5 principles of Lean Thinking

What is a business process?
Value adding and non-value adding activities
Definitions of waste - spot the worker!
The 7 classic wastes
Waste measurement
Practical Process Mapping
Maximising The Value Stream Mapping.

The Lean Manufacturing Programme includes the

following series of workshops.

Waste Elimination and Value Stream

Mapping

5S and Visual Management

Kaizen and Successful Shop-Floor

Improvement

One Piece Flow and Optimising Layouts

manufacturing skills

Based on the success of the 2002 programme we

continue to offer our Lean manufacturing series of
complementary training courses for 2003 which
cover all aspects of Lean Manufacturing Best
Practice. Through this programme participants will
build up knowledge and skills in the various methods
that can be employed to eliminate waste from their
products or services and in so doing boost
profitability and exceed customer expectations.

Course Information

Reducing Changeover and Set-Up TImes SMED

JIT Manufacturing and Introduction to Pull

Control

Duration:

1 day

Dates:

4 Feb, 3 Jun

Cost:

275 + VAT

Implementing Kanban Systems and

Smoothed Production

Location:

Team price
6-9 delegates
10 + delegates

225 per person

200 per person

Middle Aston House, Oxfordshire

Book on www.pera.com or call 01869 340361 or fax 01869 340659

37

manufacturing skills

5S and Visual Management

Kaizen and Successful Shop-Floor

Improvement

Significant improvements can be made to operational

performance by creating a work area which
instinctively feels right. This workshop provides a step
by step, team-based approach to create such an
environment and introduces a range of visual
methods to sustain improvement.

A literal translation of the Japanese word Kaizen is

continuous change for the better.
This workshop explores the people aspects of
Continuous shop-floor improvement and provides a
range of techniques to ensure effective
implementation within Western organisations.

Course Objectives

Course Objectives

Understand how workplace organisation supports

health and safety, operational performance and
customer impact
Be able to facilitate workplace organisation
projects
Understand the step-by-step 5S methodology
Know how to sustain and build upon the
improvements made
Identify a back at work project plan.

Course Content

Illustration of the benefits of good workplace

organisation
Categorisation of work into Runners, Repeaters
and Strangers
The 5S improvement methodology
Sort
Set locations
Stop contamination
Standardise
Sustain
Awareness of visual techniques in a range of
relevant applications.

Understand the people implications of the Kaizen

philosophy
Appreciate the importance of appropriate targets
and measures
Benchmark performance through a variety of
proven models
Understand how and when to apply suitable
problem solving techniques
Introduce a simple shop-floor tool for
effective project management
Identify a back at work project plan.

Course Content

Building effective teams

The importance of targets, measures and
benchmarking
Problem solving roadmap
Practical project management on the shop-floor.

Course Information

Course Information

Duration:

1 day

Duration:

1 day

Dates:

3 Mar, 1 Jul

Dates:

1 Apr, 4 Aug

Cost:

275 + VAT

Cost:

275 + VAT

Location:

38

Team price
6-9 delegates
10 + delegates

225 per person

200 per person

Middle Aston House, Oxfordshire

Location:

Team price
6-9 delegates
10 + delegates

225 per person

200 per person

Middle Aston House, Oxfordshire

All courses can be tailored or run in-house. Call 01869 340361

One Piece Flow and Optimising

Layouts

Reducing Changeover and Set-Up

TImes - SMED

Small batch manufacture is one of the drivers to

achieve low cost, responsive supply.
Small batches mean more changeovers and more
changeovers usually mean more down-time. This
workshop investigates a proven methodology to
reduce changeover and set-up times and encourages
the small batch mindset.

Course Objectives

Course Objectives

Understand the reasons for, and benefits of, one

piece flow production
Distinguish the needs of standard and special lines
Appreciate the risks of super machine capital
investments
Build an awareness of virtual simulation
applications
Identify a back at work project plan.

Understand the benefits of small batch

manufacture
Understand the step by step process of Set-Up
reduction
Build confidence in facilitating Set-Up reduction
projects
Identify a back at work project plan.

Course Content

Course Content

One piece flow and close coupled cells

Line layout best practices
Multi-skilling line personnel
Bottleneck management
Case study: Witness line simulation.

The definition of a change-over

The 7 steps of Set-Up reduction
The distinction between Internal and External
activities
Changeover process analysis
Poka Yoke and standard operating procedures
Case study examples.

Course Information

Course Information

Duration:

1 day

Duration:

1 day

Dates:

6 May, 2 Sept

Dates:

2 Jun, 6 Oct

Cost:

275 + VAT

Cost:

275 + VAT

Location:

Team price
6-9 delegates
10 + delegates

225 per person

200 per person

Middle Aston House, Oxfordshire

Location:

Team price
6-9 delegates
10 + delegates

manufacturing skills

In order to be able to respond to ever-changing

customer demands, manufacturers need to rise to
the challenge of building flexibility into their
production processes. This workshop explores the
application of the concepts behind cellular
manufacturing to either existing or green-field sites.

225 per person

200 per person

Middle Aston House, Oxfordshire

Book on www.pera.com or call 01869 340361 or fax 01869 340659

39

manufacturing skills

JIT Manufacturing and Introduction T

to Pull Control
Just In Time Manufacturing is about pulling customer
requirements through the production process. It has
demonstrated significant benefits in a wide range of
industries, typically in reducing inventory and defect
levels as well as improving internal communication.
Through interactive presentation and a table-top
simulation game, this workshop investigates the
principles behind JIT, and explains exactly how
Kanban systems work. N.B. A minimum of six
attendees is required to run the JIT simulation.

Implementing Kanban Systems and T

Smoothed Production
Kanban systems are at the heart of Just in Time
manufacture. This workshop outlines practical
aspects of designing and introducing robust Kanban
systems that work. We also investigate Takt time as a
means of regulating output to meet customer
demand and establishing a smoothed production
sequence to level any erratic pull on line-side
supplies.
Course Objectives

Course Objectives

See how all the Lean principles work together to

meet customer needs
Understand the benefits of Just in Time manufacture
Gain an exposure to a number of successful Kanban
applications
Be enthused to apply the lessons learned to their
own production lines
Identify a back at work project plan.

Course Content

Course Content

Linking Lean principles to Just in Time manufacture

Comparing Push and Pull control systems
Introduction to Kanban systems
Card and call based Kanban systems
Preferred environment, rules and implications of
Kanban
Table-top, Just in Time simulation game.

Kanban design decisions

Calculating Kanban quantities
Step by step methodology to successfully
implement Kanban
The law of industrial dynamics Forresters Law
Introduction to and calculation of Takt time
Practical applications of Takt time
Implementation case study.

Course Information

Course Information

Duration:

1 day

Duration:

1 day

Dates:

28 July, 3 Nov

Dates:

21 Aug, 8 Dec

Cost:

275 + VAT

Cost:

275 + VAT

Location:

40

Gain an exposure to a wide range of practical

Kanban signals
Learn a step by step methodology to design and
implement Kanban systems
Understand how to calculate required Kanban
quantities
Understand the practical application of Takt time
Build confidence in introducing Kanban systems
within the work environment
Identify a back at work project plan.

Team price
6-9 delegates
10 + delegates

T
225 per person
200 per person

Middle Aston House, Oxfordshire

Location:

Team price
6-9 delegates
10 + delegates

225 per person

200 per person

Middle Aston House, Oxfordshire

All courses can be tailored or run in-house. Call 01869 340361

Total Productive Maintenance

and OEE

This course conveys a practical and implementable

understanding of production planning and control
concepts to those in your organisation who have to
make it work.
The course will equip them to assess, evaluate and
develop the systems back in their working life with
the aim of contributing effectively to the
improvement of business performance.

Course Objectives
Course Objectives

Understand the principles of Total Productive

Maintenance
Build confidence in facilitating process
improvement workshops
Be able to measure the OEE of particular processes
Identify a back at work plan of action.

Course Content

Introduce delegates to
techniques in manufacturing control
practical applications of these techniques.

With particular emphasis on MRP and JIT and how

they can be complimentary.
Course Content

TPM concepts
5 pillars of TPM
Introducing Overall Equipment Effectiveness (OEE)
Autonomous & planned maintenance
People training & skills
Early equipment management
Linking TPM and Lean Manufacturing
Targeting TPM improvement areas
Your TPM implementation plan.

The role of manufacturing within the business

Forecasting tools and techniques
Stock management
MRPI & MRPII
Scheduling tools and techniques
Mathematical models and simulation
Computerised planning tools
Line balancing and Takt time
Just In Time.

Course Information

Course Information

Duration:

1 day

Duration:

2 days

Dates:

28 Jan, 24 Jun

Dates:

4-5 Feb, 13-14 May, 12-13 Aug,

4-5 Nov

Cost:

275 + VAT

Cost:

550 + VAT

Location:

Melton Mowbray, Leicestershire

Location:

Team price
6-9 delegates
10 + delegates

manufacturing skills

The key to effective Manufacturing is process

reliability. Total Productive Maintenance (TPM) aims
to maximise the man-machine interface by ensuring
that processes are consistently operating at their
optimum condition. Overall Equipment Effectiveness
(OEE) is the measure of TPM and can be used to
monitor process performance or more importantly
identify areas for process improvement.

Effective Production Planning &

Control

225 per person

200 per person

Middle Aston House, Oxfordshire

Book on www.pera.com or call 01869 340361 or fax 01869 340659

41

manufacturing skills

Design for Manufacture and

Product Customisation

An estimated 80% of manufacturing cost is decided

on the drawing board, for this reason breaking down
the barriers between Design and Manufacture is
essential in todays marketplace. Further competitive
advantage can be derived from offering products
which are tailored to meet specific customer
requirements without incurring the premium prices
which are usually associated with the supply of
Specials. This workshop provides a range of design
methods to facilitate efficient manufacture and a
design framework in which last minute product
configuration offers customised products within the
cost and lead-time expectations of mass production.

Geometric Dimensioning and

Tolerancing
This course is compiled for those who need an
understanding of Geometric Dimensioning and
Tolerancing and the fundamentals of applying it. It is
not specific to a single standard but includes the
difference between the two common standards, ISO
and ASME Y14.5 1994.
Course Objectives

Course Objectives

Understand the concepts behind design efficiency

Be able to apply some simple design rules for
effective manufacture
Gain exposure to the principles of Late Product
Configuration
Examine products in order to identify areas for
improvement
Identify a back at work plan of attack.

Course Content

Understand the latest developments in Geometric

Dimensioning and Tolerancing
Know the use and the meaning of the Geometric
symbols
Read and apply GD&T to drawings and concepts
Develop an understanding of design concepts.

Course Content

Co-ordinate drawings
Symbols and terms
Datum system
Form controls
Position controls
Introduction to MMC concept
Orientation controls
Profile controls
Co-axial controls
Co-planar controls.

Estimating design efficiency

10 golden rules of design for manufacture
Introduction to Late Product Customisation
Customer value
Product configuration
Modular design
JIT manufacture
Table-top exercise to illustrate the best design
practices.

Course Information

Course Information

Duration:

1 day

Duration:

3 days

Dates:

20 May, 18 Nov

Dates:

10-12 Feb, 7-9 May, 4-6 Aug,

17-19 Nov

Cost:

275 + VAT

Cost:

750 + VAT

Location:

Melton Mowbray, Leicestershire

Location:

42

Team price
6-9 delegates
10 + delegates

225 per person

200 per person

Middle Aston House, Oxfordshire

All courses can be tailored or run in-house. Call 01869 340361

Electrical Engineering for NonElectrical Personnel

Course Objectives

Demonstrate a knowledge of the fundamental

laws governing Electrical Engineering
Recognise common electrical components,
including relays, contactors and motors
Understand how common electrical components
function
Understand the terminology used in Electrical
Engineering
Be aware of the dangers and safety procedures
associated with Electrical Engineering
Effectively converse on electrical topics with
electrical personnel.

This course is aimed at personnel who, as part of

their job function, will be exposed to, or who will be
expected to work in, an electrical environment with
a minimum of supervision. It will suit mechanically
biased maintenance staff, supervisors, technicians
and managers.
In the interests of safety and to ensure maximum
benefit from this course, delegates must have a good
grounding in electrical theory which can be gained
on the `Electrical Engineering for Non-Electrical
Personnel course.
This is a hands on course where delegates will be
using a variety of industrial grade test instruments to
perform functional tests on electrical components
and circuits, reading standard electrical drawings and
completing fault finding exercises on a 240/415
(230/400) volt system.
Course Objectives

Course Content

Generation of electricity
Inductors and transformers
Personal safety
The electro magnet
Relays
Solonoids
Contractors
Electric motors
Motor controls
Wiring and distribution
IEE regulations
Correction equipment
City & Guilds exam.

Understand safety implications

Demonstrate a knowledge of analogue/digital
multimeters
Apply insulation, clampmeter and voltage testers
Know how to read and use electrical
drawings/symbols
Understand how to test AC/DC motors.

Course Content

manufacturing skills

This is a theoretical based course with extensive

demonstrations to illustrate how electrical
components function with examples of common
components, and how they are combined to form
electrical circuits. It has been designed to cover all
the major aspects of Electrical Engineering, which
may be found in a manufacturing environment.

Practical Electrical Engineering

Safety issues
Analogue and digital multimeters
Clampmeters
Electrical diagrams
Electrical symbols
Fault finding exercises
Motor control systems
City & Guilds exam.

In the interests of safety, delegates should have a

basic training in electrical engineering or have
completed Electrical Engineering for Non Electrical
Personnel.
Course Information

Course Information

Duration:

3 days

Duration:

3 days

Dates:

21-23 Jan, 18-20 Mar, 20-22 May

22-24 Jul, 23-25 Sept, 11-13 Nov

Dates:

18-20 Feb, 15-17 Apr, 17-19 Jun,

19-21 Aug, 21-23 Oct, 9-11 Dec

Cost:

800 + VAT

Cost:

850 + VAT

Location:

Melton Mowbray, Leicestershire

Location:

Melton Mowbray, Leicestershire

Book on www.pera.com or call 01869 340361 or fax 01869 340659

43