Cost Reduction for Manufacturing to Enhance Profitability (EMS101)

19 September 2017 - 20 September 2017

INTRODUCTION
As Malaysia is currently developing rapidly towards globalization and facing fierce competition from other developing countries, we have to be fully equipping ourselves with relevant Manufacturing Practices to improve our business position. This course is designed to develop a full view of Cost Reducing techniques for Manufacturing Operation application.

This course will be conducted with practical examples and also provide the basic concepts to all participants. If we review our current manufacturing practices and systems, it is very easy to find losses. These losses may be a result of human, materials, power and facility, machines as well as management losses. In order to achieve a more cost effective operation and become more competitive, appropriate Cost Reducing Techniques should be employed to eliminate all or some of losses suggested. This course will provide the basic steps and approach to perform cost reducing activities.

OBJECTIVES
This training session intends to expose all participants to the following concepts and applied them at appropriate situations:
• Understand and identify the losses of your operations
• Improved manufacturing process and practices to meet today’s demands of continuous changes
• Develop improvement projects to eliminate the losses
• Practice the most up to date manufacturing techniques to improve the process and productivity
• Conduct appropriate engineering or technical improvement to enhance machine efficiency
• Install a new working culture among our employees to meet future challenges
• Establish a new outlook of production flow and set up
• Develop roadmap for total customer satisfaction

 

COURSE OUTLINE
MODULE 1: PROFITABILITY AND COMPETITION IN BUSINESS
• Competition in today’s business
• Structure of production cost today
• Issues faced by today’s company
• Comparison of companies in US, Japanese, Malaysia and newly developed countries in terms of production cost

MODULE 2: LOSS COST STRUCTURE
• Losses in Manufacturing
   - Machine/Equipment Losses
   - Materials, Process, Facility, Layout Losses classification
• Derivation and stratification of loss in manufacturing
• Administration and Management Losses
   - Office Losses
   - Layout Losses
Exercises: Establish the Loss Structure of your company

MODULE 3: IDENTIFY IMPROVEMENT PROJECT (Workshop)
• Definition of Losses
• Identify Critical Losses
• Application of Analytical Tools
   - Why-Why Analysis
   - Phenomena Mechanism (PM) Analysis
Group Exercises: Using above analytical tools to solve your line problem

MODULE 4: DEVELOP IMPROVEMENT ACTIONS AND ACTIVITIES (Exercises)
• Application of Engineering and Technical Knowledge in deriving solutions
• Examples of technical “Kaizen”
• Implementing Kaizen in the right way
• Proliferating Kaizen to all equipment/machines and perform relevant tracking
• Exercises: Develop Simple Kaizen for Real Life Examples
• Cost Saving Computation. – Cost of Avoidance & Actual Savings

MODULE 5: OUTSOURCING OR SUBCONTRACTING, MATERIAL MANAGEMENT AND IMPROVEMENT
• Criteria for Outsourcing, Material Vendor Selection and Management
• Cost Saving Computation from Sub-Contractor & Material Improvement

MODULE 6: LINE SETUP IMPROVEMENT
• Benefits of cell layout as compared to conventional layout
• Operator Skills enhancement through training and On-Job-Training (OJT)
• Operator Skills Measurement Indices
   - Speed
   - Accuracy
• Working template for Operator skills measurement
• Operator UPH (Unit per hour) measurement and computation for improvement
Exercises: Develop plan to improve your operator UPH

MODULE 7: EQUIPMENT MAINTENANCE PROGRAM
• Types of Maintenance Activities
• Desired Skills from Technicians and Technical group
• Machine performance e.g. UPH, MTBF, MTTR and other Measurement
• Desired Machine Criteria
• Distribution of Maintenance Activities among all level of employees
• Implementation of TPM activities
• Workshop & Video: Develop your implementation plan for “Effective Maintenance System” and video on effects of TPM

MODULE 8: CONCLUDING REMARKS
• Future way of life
• Leadership and Team Spirit
• Role of Goals and Targets
• Continuous Learning
• What’s Next?
• Questions and Answers

WHO SHOULD ATTEND
All Production Personnel, Executives, Engineers and Managers should find this course provide a breakthrough view for modern manufacturing operation and useful for future development. Other functional support groups such as Quality, Purchasing, Materials, R & D, and Subcontracting will find this course able to enhance their skills in helping their organization to achieve “Cost Effective Operation”

METHODOLOGY
This session will be conducted in workshop manner. Real examples from the participant lines will be used as case study and applied as working examples. Apart from the workshop, the course also will have lectures and group study. Appropriate video on “Cost Saving” projects example will be shown during the training.

TRAINER’S PROFILE
MS PF LAI has a Bachelor in Engineering (2nd Class Upper Honours) from The University of Malaya. She was attached to well-known Local Contract Manufacturing Company for the last 11 years where she had hands-on experience in the Quality, Quality Systems and Process Engineering.

Her success in her career include ISO9000 certification, TPM implementation, taking responsibility to develop quality systems for various procedures and involvement in in-process problem solving and yield improvement programmes, developing training materials, measurement and evaluation systems, new product specifications and standard operating procedures.

She has been involved in teaching and training for the past 11 years and has conducted trainings in quality, quality systems and technical areas. Her hands-on experience in manufacturing as well exposure in training personnel from diverse industries in Malaysia enables her to provide a good insight to troubleshooting process problems and improving overall quality as well as latest developments in the quality arena.

Below is list of more popular trainings she conducted currently:
1. 8D
2. FMEA
3. SPC
4. DOE
5. Practical Statistical Application in Industry.
6. Quality Tools


SIM LAM THONG (TQC & TPM, 5S/6S, Project Management Consultant) has more than 23 years of vigorous involvement in TQC/TPM/5S/6S activities, Statistical Application, GD&T, Problem Solving and Project Management training. He has a lot of "Hands on" and practical experience on SPC/ SQC/ QCC/ TQC/ TPM/ TS16949 implementation, statistical application for industry’s measurement and part tolerancing, 5S/TQC/TPM audit and providing in-house consultation services to many local and overseas companies.

He specializes in Quality, GD&T, 5S/6S, TQC, SPC, 6σ quality implementation, Productivity and TPM training/consultation, Industrial Statistics Application and Design of Experiments Training and implementation. He has vigorously involved in implementing and developing 5S/TQC/QCC/TPM Activities in many local multinational and has presented many technical working papers in local and international Quality Conventions such as ICQCC in Hong Kong, Japan and others. He has been conducting training for many multinationals such as Renesas Semiconductor, Hitachi Metals, Hitachi Consumer Products (KL), ICI Products (M) S/B, Hewlett Packard, Acer Computers, Mabuci Motors, VDO, B Braun Medical Industries, Fairchild Semiconductor, Motorola Penang, ACM
Chemical, Seagate Penang, Hong Yuen (Hong Kong) and many local companies such as Daibochi (M) S/B (Melaka), Malaysian Rubber Gloves, Belton Industries etc. He has also help Hitachi Semiconductor and Hewlett Packard (M) S/B won the Malaysian National Champion in National QCC Convention in 1995, 1996 & 1997.

Prior to working as a consultant he has been working as a TPM/TQM Manager for a large multinational company for 12 years. He has been actively working with engineers to solve engineering and designing problems and application of statistics.

He is currently the TQC/TPM, 6σ Quality, Statistics, 5S and Management Consultants for Shin Etsu Handotai (Shah Alam), Osram, On Semi, Agilent, Samsung Corning, Unisem, Linear Semiconductor, Tessy Plastics (Shanghai), Diethlm Aluminium Works (Singapore), Matsushita Electronic Motor, Renesas, Seagate Penang, Carsem Semiconductors and TFP Plastics. Areas covered including Total Productive Maintenance (TPM), TQC, Measurement Uncertainty & Calibration implementation, Statistical application for 6 sigma and Continuous Improvement. He has also been a 5S consultant for Malayan Flour Manufacturing (MFM) Groups of companies.

He possesses a B.Sc. Ed. (Hons.) (Mathematics/Physics) and M. Sc. (Taguchi Experimentation) both from USM, Penang. He can communicate in English, Bahasa Malaysia and Mandarin with major dialects such as Cantonese and Hokkien.

DURATION
2 days

COURSE FEE
Program 100% Claimable under SBL Scheme
PSDC Members: RM 690/pax
Non-Members: RM 750/pax

*All prices listed above are subjected to GST effective 1st April 2015