Lean Manufacturing Operation for Profitable Production (EMS103)

25 April 2017 - 26 April 2017

INTRODUCTION
As Malaysia is currently developing rapidly towards globalization and facing fierce competition from other developing countries, we have to be fully equipped ourselves with relevant Manufacturing Practices to improve our business position. This course is designed to develop a full view of Manufacturing so that it covers the necessary activities to support a very lean and effective Manufacturing Operation. In this aspect, we will achieve the basic business performance indices such as Productivity, Quality, Cost, Delivery, Safety and Morale through a proper implementation of well planned activities in our organization.

This course will be conducted with practical examples and also provide the basic concepts to all participants. It is generic and can be applied to all types of industries. As the title suggested, the ultimate aim of this course is to provide participants a platform of activities to achieve a very lean manufacturing environment and thereby bring the organization to a better level of competition in their business sectors.

OBJECTIVES
This training session intends to expose all participants to the following concepts and applied them at appropriate situations:
• Set up appropriate lean production line structure to achieve best profit
• Improved manufacturing process and practices to meet today’s demands of continuous changes
• Develop the appropriate performance measures for “Lean Manufacturing Organization”
• Apply “Quick Change Over” techniques to adapt the constant demand change or model change
• Develop effective external partnership such as Supplier Management, Vendor Management and Subcontractor Management
• 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: WORKING TOWARDS “LEAN MANUFACTURING COMPANY”
• Completing the Change Process
• Definition of “Lean Manufacturing – World Class Company” today
• Issues Faced by today’s company
• Comparison Between US and Japanese Companies’ Management, Manufacturing System and Philosophies
• Workshop: Gap Analysis of Our Company Performances Vs “World Class Companies”
• Video: “The need for Changes”

MODULE 2: LEAN MANUFACTURING OPERATION FUNDAMENTALS
• Strategic Management
• Design for Manufacturability
• “Consumer In” Marketing Strategy
• Simplified Flow Control in Production
• Zero Inventory System
• Quick Change, Set Up, Start Up and Development
• Eliminate All Non-Value Added Processes and Bottlenecks
• Line Balancing Techniques
• Leveled Production
• Total Productive Maintenance
• Workshop: Develop Your Implementation Plan For “Lean Manufacturing Operation”

MODULE 3: LEVEL PRODUCTION
• Production Planning and Control Techniques
• The Needs To Level The Production
• Techniques For Production Leveling
• Application Of Prediction And Forecasting Techniques In Demand Planning
• Line Balancing Techniques
• Practical Calculation Case In Electronic Factories

MODULE 4: STANDARD OPERATION
• Job Skills Classification
• Job Design And Planning
• Standard Operation For Operator’s Job
• Develop Job Skills Measurement For Any Assignment
• Application Of Standard Operation For Production Activities
• Benefits Of Standard Operation
• Examples Of Standard Operation In An Assembly Industries

MODULE 5: CHANGE OVER
• Concepts Of Single Minute Change Of Die (SMED)
• Application Of Hooks And Catches
• Elimination Of Tedious Tightening, Alignment And Calibration
• Kaizen Cases for SMED
• Benefits Of SMED
• Practical Application In The Lines

MODULE 6: FLOW MANUFACTURING
• Concepts Of Flow Manufacturing
• Criteria For Flow Manufacturing
• Application Of Small Lot Operation
• Smothering Of Line Flow Process By Proper Layout And Logistic Control
• Example On Flow Manufacturing Cases And Calculation


MODULE 7: JIDOKA CONCEPTS IN MACHINE DESIGN
• Application Of Automation
• Human Factor Consideration
• User Friendly Set Up
• Kaizen On Existing Machine
• Reduction On Cycle Time And Job Simplification
• Examples And Exercises

MODULE 8: CONCLUDING REMARKS
• Future Way Of Life
• Leadership and Team Spirit
• Role of Goals and Targets
• Continuous Learning
• What’s Next?
• Video: “Future Development in Factory Management”
• Questions and Answers

METHODOLOGY
This session will be conducted in a workshop manner. Real examples from the participant lines will be used as case study. Apart from this workshop, the course will have lectures and group study. Video on “World Class” Practices will be shown during training.

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

TRAINER’S PROFILE
SABRINA LIM has a Bachelor in Engineering (First Class Honours) from The University of Sydney. She was attached to well-known American MNCs where she had hands-on experience in the Quality, Quality Systems and Process Engineering.

Her success in her career include ISO9000 recertification, taking responsibility for product transfer from the US, troubleshooting new product quality problems and involvement in in-process yield improvement programmes, developing training materials, calibration systems, new product specifications and standard operating procedures.

She has been involved in teaching and training for the past nine 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 and Singapore enables her to provide a good insight to troubleshooting process problems and improving overall quality as well as latest developments in the quality arena.


DURATION
2 days @ 9am-5pm

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

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