LEAN MANUFACTURING

Program Overview

Lean manufacturing is a great competitive weapon that reduces your costs, improves quality and improves your bottom
line. It is aimed at the elimination of waste in every area of production including customer relation, product design,
supplier networks and factory management. Its goal is to incorporate less human effort, less inventory, less time to
develop products, and less space to become highly responsive to customer demand while producing top quality
products in the most efficient and economical manner possible.

Target Participants

Factory Manager, QA Manager, Production Manager , Production Supervisor and Executives.

Learning Objectives
To provide knowledge and skills to the participants on:

 Value Add Manufacturing.

 Flow System Manufacturing.
 Cycle Time Reduction.
 Waste Reduction.
 Inventory and Space Reduction.
 The steps required to develop a current and future value stream mapping.
 Opportunity to practice some of the techniques.

Methodology:

 Presentation
 Case Studies
 Videos
 Self Audit & Assessment
 Group Work/Exercises for development of practical tools
 Action Plan Development
 Follow-up on Effectiveness of Training

Course Contents

INRODUCTION
 Why lean manufacturing?
 Lean concept.
 The importance of lean manufacturing.
MODULE 1 (MASS PRODUCTION)
 Evolution of manufacturing.
 Mass production environment.
 Traditional steps in manufacturing.
 Value Stream Mapping.
 Process Mapping Techniques.
 Group Exercise – Project Work Phase 1.

MODULE 2 (WASTE MANAGEMENT)

 What is waste?
 Types of waste.
 Causes of waste.
 Types of inventory.
 The functions of inventory.

MODULE 3 (LEAN PRINCIPLES)

 What are the lean principles?

 Value adding activities.
 Non-value adding activities.
 Manufacturing lead time.
 Group Exercise – Project Work Phase 2.

MODULE 4 (LEAN PRODUCTION)

 Evolution of manufacturing.
 Lean production environment.
 Lean lay-out.
 The advantages of having lean lay-out.
 U-Line advantages.
 Group Exercise – Project Work Phase 3.

MODULE 5 (LEAN TOOLS)

 Flow system.
 Pull system.
 Quick change over.
 Mistake proofing.
 Problem solving.
 Group Exercise – Project Work Phase 4
MODULE 6 (LEAN PARTNERSHIP)

 Customer supplier partnership.

 Characteristics of lean partnership.
 5 “S” housekeeping and benefits.
 Lean strategy and implementation – Group Presentation.
 Continuous improvement through perfection.

Q&A

Evaluation & Close

Program Duration
2 days Training and Project Coaching

Program Fees
In house Program – RM4000/ Per Day Training and Coaching

Contact Person
Mr.Thangamany – ICS Certification (M) Sdn Bhd

Address
No. 9, Tkt. 1, Jalan Tampin , Taman Bukit Emas ,70450, Senawang, Negeri Sembilan, Darul Khusus

Telephone & Fax /Mobile/Email

06-6784824/ 016-2159355 / info@icscer.com