Overview
KAIZEN is a Japanese word meaning gradual and orderly, continuous improvement. The KAIZEN business strategy involves everyone in an organization working together to make improvements 'without large capital investments'. KAIZEN is a culture of sustained continuous improvement focusing on eliminating waste in all systems and processes of an organization. It is everybody’s business to continuously improve their ability to meet expectations of high quality, low cost, and on-time delivery. KAIZEN transforms companies into 'Superior Global Competitors'.
Learning Outcomes
On completion of The Kaizen Process of Continuous Improvement Program, participants will be able:-
- Problems are identified at source, and resolved.
- Small improvements which are realized can add up to major benefits for the business
- Improvements, which lead to changes in the business quality, cost and delivery of products, mean a greater level of customer satisfaction, and business growth.
- By involving employees in looking at their environment to bring about change, results in improved morale as people begin to find work easier and more enjoyable.
Who Must Attend
- Factory Manager / Production Manager / Executive / Supervisor
- Materials Manager/Executive/Officer
- Warehouse/Store Manager / Executive/ Supervisor
- Production & Materials Planner / Manager
- Purchasing Manager, Executive, Buyer
Course Details
Day 1 :
Module 1: Overview
The Theory behind Kaizen
Since Kaizen is often interpreted differently by the companies that use it. Participants will be introducing to the variations represent the components of Kaizen that become associated with various operational objectives:
- Manufacturing best practices
- Tools for eliminating waste
- Understand and apply the Quality Planning tools.
- Identify and apply the Quality Control tools.
- Identify and utilize Quality Improvement tools
- How to carry out their Process Capability studies.
- Understand Basic Statistics and Basic Anova.
- Creating standards
- A co-operative environment
- A creative workforce
- Lean manufacturing
b) Theory
- What is Kaizen?
- Why Kaizen?
- What is Waste?
- Value-Added, Lean & Flexible Manufacturing
- People: The Heart and Mind of Kaizen
- The Kaizen Principles
- The Ten Basic Tips for Kaizen Activities
Module 2: Lean Techniques
- 5S
- Single Minute Exchange of Die (SMED) also known as Set-up Reduction :
- Total Productive Maintenance (TPM)
- Standard Work
Day 2:
Module 3: Kaizen Tool
- Pareto Charts:
- Ishikawa (Fishbone) Diagram:
- Histograms
- Check-Sheets
- Five “Why?” Root Cause Analysis: Getting to the root
- Brainstorming and Consensus Decision Making: Facilitation Techniques
- Process Mapping
Module 4: Analysing Charts
- Scatter Plots
- Statistical Process Control
- Gantt Charting:
- Kaizen Event Planning
Methodology
Lecture, Discussion & Case Studies.
Course Leader
Pathir G.
Consultant – Certified Lean 6-Sigma Black Belt Trainer
B.Sc (Hons) in Science & Technology (Mathematics) – University Malaya, Malaysia.
Higher Secondary/STPM/"A" Level/Pre-U (Chemistry, Mathematics, Physics) - Methodist High School, Malaysia
Certified Lean 6-Sigma Black Belt ,Certified Six Sigma Green Belt / Project Manager - General Electric (USA) Malaysian Appliance Control.
Mr. Pathir was trained in USA and Singapore in Six-Sigma Methodology and Tools (Black Belt) and upon his return to Malaysia, he was sent to China to train the Engineers in Nidec Corporation situated in Dalian., manufacturer of Spindle Motors, Mini Fan Motors and other types of motors on Six Sigma Methodology and Tools.
Pathir then joined Thong Fook Plastics (M) Sdn. Bhd. as a QA Executive heading the QA Dept manufacturing all kind of plastic bags through extrusion process, and later promoted to Technical Executive in-charge of Plastics Injection Moulding Division. He earned Certificate in Plastics Materials and Injection Moulding Process issued by CIAST, Ministry Of Labour. He was trained 6 months in Plastics Injection Moulding at Minolta Precision (M) Sdn Bhd.
His next assignment was Production Manager for Nidec-Copal, a Japanese MNC which is an Optomechatronics company producing Stepper Motors, Trimmer Potentiometer, Clik Motor, PCB Assembly, Fan Motors, Injection Moulding and Metal Stamping. He has led this company to achieve ISO9000 as a Management Representative. He has been trained as a Lead Assessor by QMS and Internal Quality Audit by SIRIM. Pathir was a Production Manager for eight years before joining an American MNC (General Electric USA Malaysian Appliance Components) as Materials & Customer Service Manager.
Pathir’s five years as a Materials & Customer Service Manager have improved productivity of more than US$1,800,000.00 through Six-Sigma activities. He has been certified Green Belt in 2001 but has been a trained Black Belt since 1999. He also received the Phillippe Award 2000 for Distinguished Community Leadership and also completed the Advance Manager’s Course in 2001 conducted by GE.
He is knowledgeable in other areas such as EHS, Ergonomics, ISO 9001:2000. He owns the Chemical Management Framework while in GE. He has been the Chairman of Health and Safety committee for 2 years.
His next portfolio was as a Technical Advisor for the Plastics Division and a Training Consultant for Six Sigma Methodology and Tools for NCPC, an Japanese MNC in the Philippines. He completed many improvements in the Plastics Division through DOE applications for parameters characterization and Optimization. He also trained all Engineers and Managers in NCPC from various departments like Plating, Motors, LED/SMD, Plastics, Metal Stamping, HR and Materials on Six -Sigma Tools (DMAIC).
He also trained NCPC’s customers on DOE application using Minitab 14 Statistical Software and have also taught other customers (Vishay Semiconductor) in Manila (Philippines), Melaka (Malaysia) and in Shanghai (China).
His last assignment was with Exas Philippines Inc. in Cebu and Aikawa Philippines Inc. in Batangas, Philippines as Technical Advisor to the Plastics Dept and a 6-Sigma Training Consultant. His contract expired March 2007 and since then has returned back to Malaysia.
Training and Coaching for Engineers and Managers in Indonesia - Perawang, Pekan Baru, Jambi, Surabaya and Jakarta in 6-Sigma Green Belt level since May 2008 to end August 2008. These are Pulp and Paper mills in Indonesia.
Pathir also conducted 6-Sigma and other related programs for Proton, Perodua, Petronas, Samsung, NSK Bearing, Konica-Minolta, Nitto Denko,Tesco etc in Malaysia.
He has the capability of identifying improvement opportunities in any manufacturing operations and also possesses problem-solving capabilities. He has conducted many trainings for both In-House and Public Courses in Kuala Lumpur, Penang and Johor. Other than 6-Sigma Modules, he also teaches Effective Materials Management, Production Planning & Inventory Control, Statistical Forecasting, How to be an Effective QA, The New 7 Seven QC Tools, Cost Reduction Techniques for Manufacturing, 3Q6S, 6-sigma tools for improvements, Pengurusan Stor & Inventori Secara Berkesan, FMEA, MSA, Sampling Techniques, Regression models, DOE,RSM, QCC & 7 QC Tools, SPC, Enviromental Spills (Hazardous Toxic Substances), Simple, Multiple & Logistic Regression, COPQ, etc.
He also provides excel-based tools for all applications in their respective fields.
Testimonies
Investment
| Normal Fee |
| Sign up 1 pax |
| Pay before course starts |
| MYR 1,590.00 |
| USD 480.00 |
| Early Bird |
| Sign up 1 pax |
| Pay 14 day(s) before course starts |
| MYR 1,390.00 |
| USD 430.00 |
| Group Fee |
| Sign up 3 pax or more |
| Pay 14 day(s) before course starts |
| MYR 1,290.00 |
| USD 410.00 |
Upon successful completion of this program, you will receive a Certificate of Achievement.
Payment mode:
1. ONLINE PAYMENT by Credit card: You can opt to register and pay online with our latest payment integration system through our website.
2. Telegraphic Transfer- You can also opt to use GIRO or telegraphic transfer of payment via international banks.
