Lean Business Solutions PLT (LLP0003236-LGN)

MANUFACTURING ESSENTIALS 2020

“Key to understanding world class manufacturing”

 

INTRODUCTION

Manufacturing industry are evolving rapidly that requires investment to keep up with to-date technology and at the same time are striving to maintain competitiveness. More importantly, the utilization of resources i.e. materials, machineries and people are expected to be optimized and effective to ensure products produced at a minimum cost per unit and meeting required specifications. Never has a program be made to be such comprehensive to all elements of manufacturing. This course covers 3 major components that are key to world class manufacturing such as Lean production, Total Quality Management (TQM) & Total Productive Maintenance (TPM). Other sub components such as Industrial 4.0, cybersecurity, Costs of Quality, and the Evolution of Manufacturing will also be covered. After this course, participants will be able to immediately start working on cost reduction and continuous improvements projects. This is because this course will be very practical and also be done in a workshop method. This program is not like an ordinary lecture / training as participants are required to actively participate in practical activities which is built-in to every module. Every module will stimulate the minds of participants in order to go back and put this knowledge into immediate use.

BENEFITS

  1. Have awareness on industrial challenges.
  2. Will be able to understand lean production and it’s tools for cost improvement / continuous improvement projects.
  3. Have awareness and basic understanding on Total Productive Maintenance (TPM).
  4. Understand the importance Total Quality Management (TQM) and how to contribute towards achieving zero defect.
  5. Provide a visible management system.
  6. Understand the link among lean production, total productive maintenance and total quality management.

TARGET AUDIENCE

  •  Fresh graduates, newly recruited and existing engineers or executives.
  •  Quality, Maintenance, Production & Manufacturing Personnel

METHODOLOGY

In order to enhance effective optimum learning and ensure the participants receive maximum benefits, the trainer will use the following methodology:

  • 50% Practical Activities
  • Informative presentation

      Your trainer is skilled at sharing information in a way that's engaging. Just sit back and take it all in.

  • Group exercises

      You'll do some of these alone, and others with groups or a partner.

  • Group discussion

      Get your questions answered. Share your point of view. These are some of the most stimulating segments of the program.

  • Video Presentation
  • Simulations
  • Real Case Studies and Manufacturing Examples

DURATION, FEES & VENUE

  • Fees inclusive of training fees, participant’s handouts / course materials, venue, refreshments and Certificate of Attendance).

  

DATE

DURATION

FEES

VENUE

24th & 25th March 2020

 

 

2 Days - 9am to 5pm

 

RM1250 / person

  

 

Holiday Villa, Subang

 

 

 

 

CONTENTS   

      1. MODULE 1: MODERN DAY INDUSTRIAL CHALLENGES

  • Labor shortage
  • Industry revolution 4.0
  • Cybersecurity
  • Global competition

     2. MODULE 2: LEAN PRODUCTION

  • Value added and nonvalue added times in value stream
  • Nonvalue added times are costs
  • Understanding 8 deadly wastes (D.O.W.N.T.I.M.E)
    • Defects
    • Overproduction
    • Waiting
    • Non-utilized skill
    • Transportation
    • Inventory excess
    • Motion waste
    • Excess processing
  • Type of production
    • Traditional production
    • Mass Production
    • Lean production
    • Traditional production vs. lean production

      3. MODULE 3: PILLARS OF LEAN PRODUCTION 

  • Just in time principles
    • Takt time production
    • Continuous flow
    • Pull system
  • Jidoka
    • Quality built in process
    • Automation with Autonomation
    • Poka Yoke

      4. MODULE 4: TOTAL PRODUCTIVE MAINTENANCE (TPM)

  • What is TPM?
  • Goals of TPM
  • Single Minute Exchange of Die (SMED)
  • Overall Equipment Effectiveness
    • Availability rate
    • Performance rate
    • Quality rate
  • Six big losses
    • Breakdown
    • Set-up & adjustments
    • Idling & minor stoppages
    • Reduced speeds
    • Quality Defects
    • Start-up rejects / Yield Losses

      5. MODULE 5: TOTAL QUALITY MANAGEMENT (TQM)

  • Quality Guru’s
  • The rise of Quality Standards in Manufacturing
  • What is TQM?
  • Goals of TQM
  • What is quality?
  • Costs of quality

     6. MODULE 6: THE RELATIONSHIP BETWEEN LEAN PRODUCTION, TPM AND TQM (WORKSHOP)

 

INSTRUCTORS PROFILE

MR AMOS ANDREW - BEng (Hons) Industrial Engineering, LBC

Amos holds a Bachelor of Engineering (Honors) degree in Industrial Engineering from the University of Bradford, United Kingdom. He is a registered member of the Society of Manufacturing Engineering (SME) and has served the Multinational Companies in the capacity of Senior Industrial/Lean Engineer. Thereafter we went into coaching & trainings related to continuous improvements, leadership and change management as a technical training manager in a multinational company based in Vienna, Austria. Being trained in Japan under Toyota and benchmarking various world class companies in Japan such as Mitsubishi Motors, Lexus, Toto, Denso and many more, Amos holds a high credibility in sharing his experience from the best manufacturing companies in the world.

 

He specializes in Lean Manufacturing, 6S Implementation, Problem Solving, Work Study / Time Study, Kaizen Implementation and Leadership Skills. With his 10 years of hands on knowledge and experience in various manufacturing industries, he has coached, trained and developed many participants to appreciate why these techniques are so important in helping companies to compete in the global economy. Amos has also been awarded the Lean Bronze Certification, USA and the Global Leadership Train the Trainer Program. Maynard has certified him as a Blue Card Holder of Basic MOST, which is a work method standardizing technique in industrial Engineering. In 2018, Amos went to Vienna & was trained under FCA with regards to World Class Manufacturing under the pillar of People Development.

 

Amos has also done various hands-on continuous improvement projects throughout his career. He has trained many multinationals such as Shell, Top Glove, Affin Bank, Semperit Group, Pen Group, CJ Bio, Recron, Johnson Matthey, KESP, South East Technologies, Mattel and many more. The classes he conducts are full of real case samples and case studies that make the learning very practical, beneficial and lively with a lot of interactions. Participants really enjoy his training sessions where great scholarship, great leadership and great character are systematically demonstrated. His assets are sharing his industrial experiences & different cultures to make the training interesting and lively with a lot of take away for the participants. Participants will also get their mind stimulated in every segment and also start finding ways of practical implementation. He is also well versed in English and Bahasa Malaysia.

Lean Business Solutions PLT is certified with Pembangunan Sumber Manusia Berhad (PSMB) / Human Resource Development Council (HRDC). Our trainer, Mr. Amos Andrew is also certified under the Train-The-Trainer program - # TTT/11960

 

Registration Form - MANUFACTURING ESSENTIALS 2020

 

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