Quality Dynamics Consultancy Sdn Bhd presents

Nov 29 - 30, 2010 (9am - 5pm) at Holiday Inn Glenmarie, Shah Alam

Lean Manufacturing

(by Mr. S. Gopalakrishnan )

objectives

Participants will be able to:

     - Understand the terms, terminology, and benefits of lean manufacturing.
     - Conduct value stream maps of the current state, identify
        the potentials for reduced waste and improved flow, and develop
        a future state map.
     - Participate in the development of a site-specific lean
        implementation roadmap.
     - Avoid the common pitfalls encountered during lean implementation.

program content

STANDARDISE WORK
    - Benefits of Standardized Work.
    - Use standardized work basic concepts and examples from various 
       industries.
    - Observe work before you standardized it.
    - Use the elements of standardized work (take time, work sequence, 
       standard in-process inventory).
    - Identify the documents for establishing standardized work (production
        capacity sheet, combination table, work chart).
    - Define the requirements for standardized work (work, equipment 
       and line quality).
    - Standardize : poka-yoke, visual systems, checking and auditing.
    - Choose the standardization techniques suitable for your environment 
       so that you can effectively ensure your process is consistent and 
       your results are predictable.

LEAN OFFICE
    - Identify the basic principles and objectives of Lean.
    - Define how continuous improvement in an ongoing activity and must 
       be constantly reinforced.
    - Define how change must be sponsored by management and move 
       down through the organization.
    - Recognize how Lean tools and techniques help eliminate waste 
       from processes.

KANBAN
    - What is Kanban? – Definition
    - Understanding the origin of Kanban
    - Comparison of Push vs. Pull Systems
    - Kanban Card Types (withdrawal, conveyance and production)
    - Types of Kanban systems (one card and dual card)
    - Kanban System Characteristics
    - Strengths and Weaknesses of Kanban
    - Planning for Change
    - How to Implement Kanban?
    - How Kanban can interface with MRP/ERP systems?

CELLULAR WORK FLOW
    - Definition and benefits for U-shaped cell design
    - Use of multi-skilled, multi-machine operators and small 
       flexible machines
    - Use of Jidoka (Automation) to eliminate machine watching
    - Elements of a cell design
    - Process based layout
    - Standardized work, 5S and Visual Management to support 
       cellular manufacturing
    - Automation cell maintenance activities
    - Cell activity boards and measures

QUICK CHANGOVER-SETUP REDUCTION (SMED)
Reduce process changeover times resulting in greater customer
responsiveness and be able to:
    - Define and measure setup
    - Define the four stages of SMED
    - Identify Internal and External setup
    - Apply techniques to convert internal setup to external setup
    - Identify inexpensive techniques to reduce internal setup time
    - Describe how SMED relates to Lean Manufacturing especially 
       small lot production

TOTAL PRODUCTIVE MAINTENANCE
Enhance plant and equipment reliability to increase productivity and
be able to:
    - Identify the basic components of total productive maintenance
    - Describe the bath tub curve and machinery life cycles
    - Identify the Six Big losses in machinery
    - Design and implement autonomous maintenance plans
    - Train other operators in TPM activities
    - Assess the TPM needs of specific equipment to help achieve zero defects
    - Recognise faults and how to address them
    - Create a sample productive maintenance program for their plan

HOSHIN PLANNING
    - Identify key characteristics of Hoshin Planning
    - Identify differences with other planning processes
    - Define the essential elements of A3 planning documents

CULTURE CHANGE
    - Understand stages of Lean growth
    - Identify points of leverage to move Lean forward in the organization
    - Address barriers to Lean transformation
    - Assess organizational readiness to move forward

LEAN METRICS
    - Identify organizational measures that are strategically important
    - Determine front-line measures that will achieve organizational measures
    - Create visual “Box Scores” for front-line measures
    - Eliminate financial transaction

methodology

Power Point Presentation, Exercises, Group Discussions & Case Study

who must attend

MD, FM, Quality Manager, Production Manager,
Engineers instituting Lean Manufacturing

investment fee / early bird by 16/11/2010

Standard: RM 1,060.00 / RM 960.00 per participant

Group discount: RM 1,010.00 / RM 910.00 per participant for a minimum of 2 participants from the same company

(Fee inclusive of Refreshment, Buffet Lunch, Training Bag, Handouts, Writing Pad, Pen & Certificate of Completion)

registration & payment


PROGRAMS ARE CLAIMABLE UNDER SBL SCHEME

Please register online through www.qdc.com.my or call 03-78054587 / 03-78044196. Our phone line operation hours are from 8:30am to 6:00pm from Monday to Friday.

All registration MUST be accompanied with PAYMENT.

Completed registration form with CHEQUES should be made in favor of "Quality Dynamics Consultancy Sdn Bhd" and sent to:

(FEE PAID IS NOT REFUNDABLE but replacement may be made at no additional cost. Quality Dynamics Consultancy Sdn Bhd reserves the right to cancel or reschedule the above course and shall inform participants of the changes)

COURSE FACILITATOR - MR. S. GOPALAKRISHNAN

Mr. Gopalakrishnan has more than 20 years of working experience in various industries and organizations including reputable Japanese and American MNCs such as GE, Nidec-Copal, Aikawa, NCPC and others in different countries such as China, The Phillipines and Malaysia.

An experienced Six-Sigma Practitioner, Advisor and Trainer, Mr. Gopalakrishnan received his Six Sigma Black Belt training in USA and Singapore. Some of the companies benefited from his Six-Sigma training included Nidec Corporation situated in Dalian, China, NCPC and its customers, Exas and Aikawa, the Japanese MNCs in the Philippines and many others. He is also knowledgeable in other areas such as EHS, Ergonomics, FMEA, ISO 9001:2000. He owns the Chemical Management Framework while working in GE. He has been the Chairman of Health and Safety committee for 2 years.

Some of the positions held by Mr Gopal includes Technical Advisor and a Six Sigma Training Consultant to Exas Philippines in Cebu and Aikawa Philippines in Batangas, Philippines and NCPC, a Japanese MNC in the Philippines. He also trains NCPC’s customers on DOE application using Minitab Statistical Software and have also taught other customer like Vishay Semiconductor  in Philippines, Malaysia and in Shanghai, China.

Mr. Gopal’s experienced as a Materials & Customer Service Manager in GE Malaysia Appliance Components has helped to improve productivity of more than US$1,800,000.00 through Six-Sigma activities. Mr Gopal also worked with Nidec-Copal, a Japanese MNC and held the position of Production Manager.  He has led this company to achieved ISO9000 as a Management Representative. He has been trained as a Lead Assessor by QMS and Internal Quality Audit. Gopal was a Production Manager for eight years before joining GE.

A Mathematics graduate from University Malaya, Mr. Gopal ‘s wide working experiences and industrial exposure in different disciplines will bring tremendous benefits to his course participants.