STOP. LEARN. EXALT.

PROPOSAL TO

V.S.
INDUSTRY
BERHAD

FOR
LEAN
MANUFACTURING
FOR OPTIMUM
PRODUCTION
TRAINING

PROPOSAL NO: TNG-315-12

1768,
Jalan Senai Utama,
81400 Senai,
Johor Darul Takzim.
TEL: 012-7106867 FAX: 07-598 7551

STOP. LEARN. EXALT.

CONTENTS

(1) INTRODUCTION
(2) TRAINING COURSE OUTLINE &
TRAINERS PROFILE
(3) PROJECT AGREEMENT

PROPOSAL NO: TNG-315-12

1768,
Jalan Senai Utama,
81400 Senai,
Johor Darul Takzim.
TEL: 012-7106867 FAX: 07-598 7551

STOP. LEARN. EXALT.

1. Introduction
The overall objective of this proposal by EXALT CONSULTANCY are to conduct LEAN
MANUFACTURING FOR OPTIMUM PRODUCTION TRAINING for V.S. INDUSTRY BERHAD
with operations at PTD 86556, Jalan Murni 12, Murni Industrial Estate, 81400 Senai, Johor,
Malaysia.

2. Training Course Outlines &

Trainers Profile
TITLE: LEAN MANUFACTURING FOR OPTIMUM PRODUCTION
INTRODUCTION:
Today's most competitive manufacturers know that there is and know exactly what is LEAN
MANUFACTURING.
Lean manufacturing isn't just the latest industry buzzword or quick-fix alternative. Increasing
competition demands a continuous focus on minimal costs, maximum customer options, fast
delivery, and high-quality products and services. Today's manufacturers must be innovative while
focusing on waste reduction, improved lead-time, maximized flexibility, and upgraded quality.
Lean manufacturing concepts are proven strategies to help manufacturers obtain these
attributes.
Lean manufacturing is changing businesses around the world through techniques that create
outstanding results and translate directly into bottom-line profits. It's not uncommon to save tens
or even hundreds of thousands of dollars by implementing simple lean manufacturing techniques.
.

OBJECTIVES:
On completion of this course, the participants will be able to understand Lean Manufacturing as

PROPOSAL NO: TNG-315-12

1768,
Jalan Senai Utama,
81400 Senai,
Johor Darul Takzim.
TEL: 012-7106867 FAX: 07-598 7551

STOP. LEARN. EXALT.

the non waste approach to manufacturing through continuous improvement effort by focusing on
team efficiency than individual efficiency.
They will be able to have better understanding of lean manufacturing concept and its benefits i.e.
reduce lead time; reduce defect; reduce wastes; increase capacity and throughput; increase
productivity; increase customer satisfaction; and increase profitability.
By the end of the session, participants would be able to;
The objective of this program is to enable the participants to:

Identify the history development of Lean.

Distinguish the characteristics from old management to lean management.
Recognize the eight major wastes in an organization.
The Lean methodologies step by step.
Recognize the activities of (Rapid Improvement Events) RIE (Kaizen) and its team.
Identify the characteristics of a pull and push system.
Management of value creation elements in the business process.
Recognize the concepts of Plant Capacity and Customer Demand.
Identify Production flow with Customers purchase rate.
Management of workplace organization.
Recognize process flow improvement with Pull system methodology.
Method use to manage a pull system environment.
Method use to reduce time in a changeover process.
Method use to manage equipment contribution to productivity.
Method use to manage overall equipments effectiveness.
Distinguish technique in error prevention of process.
Method to recognize opportunities for time (waste) improvement in a process.
Mapping method in identifying value creation elements and improvement opportunities in
a process.

Participants will find this course to be very practical and helpful to consequently achieve
improvement across their areas of business.

PROPOSAL NO: TNG-315-12

1768,
Jalan Senai Utama,
81400 Senai,
Johor Darul Takzim.
TEL: 012-7106867 FAX: 07-598 7551

STOP. LEARN. EXALT.

PROGRAM DURATION: 2 Days

1.

Introduction What is Lean manufacturing?

Lean Manufacturing is an operational strategy oriented toward achieving the shortest
possible cycle time by eliminating waste. It is derived from the Toyota Production System
and its key thrust is to increase the value-added work by eliminating waste and reducing
incidental work. The technique often decreases the time between a customer order and
shipment, and it is designed to radically improve profitability, customer satisfaction,
throughput time, and employee morale.
The benefits generally are lower costs, higher quality, and shorter lead times. The term
"lean manufacturing" is coined to represent half the human effort in the company, half the
manufacturing space, half the investment in tools, and half the engineering hours to
develop a new product in half the time.

2.

The 7 wastes in manufacturing plant

3.

Overproduction.
Waiting
Transporting
Inappropriate Processing
Unnecessary Inventory
Unnecessary / Excess Motion
Defects

Characteristics of lean manufacturing

Single-piece production
Repetitive order characteristics
Just-In-Time materials/pull scheduling
Short cycle times
Quick changeover
Continuous flow work cells
Collocated machines, equipment, tools and people
Compressed space
Multi-skilled employees
Empowered employees

PROPOSAL NO: TNG-315-12

1768,
Jalan Senai Utama,
81400 Senai,
Johor Darul Takzim.
TEL: 012-7106867 FAX: 07-598 7551

STOP. LEARN. EXALT.

High first-pass yields with major reductions in defects

4.

Lean manufacturing elements

Elimination of Waste
Equipment Reliability
Process Capability
Continuous Flow:
Error Proofing
Stop the Line Quality System
Kanban System
Standard Work
Visual Management
In Station Process Control
Level Production
Takt Time (Takt Time = Time available to produce a product divided by the number of
parts that the customer wants to buy)
Quick Changeover
5.

Lean Manufacturing Vs Traditional Manufacturing

A.

Overall Organizational Characteristics

Business Strategy
Customer Satisfaction
Leadership
Organization
External Relations
Information Management
Cultural
Production
Operational capability
Maintenance

B. Manufacturing Methods
Production schedules are based on

PROPOSAL NO: TNG-315-12

1768,
Jalan Senai Utama,
81400 Senai,
Johor Darul Takzim.
TEL: 012-7106867 FAX: 07-598 7551

STOP. LEARN. EXALT.

6.

9 Keys to lean development

7.

Customer Focus
Leadership and Strategic Planning
Organization Architecture
Lean Supply Chain
Information Architecture
Improvement Technology
Production Management
Equipment/Process Management
Product/Process Engineering

Benefits of lean manufacturing

8.

Products manufactured to
Production cycle times are
Manufacturing lot size quantities are
Plant and equipment layout is
Quality is assured
Workers are typically assigned
Worker empowerment is
Inventory levels are
Inventory turns are
Flexibility in changing manufacturing schedules is
Manufacturing costs are

Material Handling Benefits

Inventory Benefits
Quality Benefits
People Benefits
Customer Benefits

Techniques and tools of lean manufacturing

Value Mapping
SMED (Single Minute Exchange of Dies)

PROPOSAL NO: TNG-315-12

1768,
Jalan Senai Utama,
81400 Senai,
Johor Darul Takzim.
TEL: 012-7106867 FAX: 07-598 7551

STOP. LEARN. EXALT.

9.

1-Piece Flow
KanBan (Inventory Control via Card System)
Poka Yoke (Mistake Proofing) & Jidoka
5S (Separate, Simplify, Standardize, Sustain)
Total Productive Maintenance
Visual Management
Line Optimization
Synchronous Manufacturing

Lean manufacturing process

Assessing the current process

Understanding the customer's true desires & future market trends
Training & buy-in by Sr. management
Developing profound knowledge of the manufacturing process
Applying Lean tools and techniques at the most critical processes
Spreading out the Lean implementation to all auxiliary areas until a fully integrated
manufacturing process is obtained
Implement Lean with suppliers
Implement Lean with downstream supply chain organizations, including customers
Apply Lean into off-line and non-manufacturing areas (Engineering, Design, Marketing,
etc.)
10.

Integration of 6 Sigma, Lean and Kaizen

TARGET GROUP:
Managers, Section Heads, Engineers, Supervisors, Line Leaders, production, quality
control/assurance and engineering.

PROPOSAL NO: TNG-315-12

1768,
Jalan Senai Utama,
81400 Senai,
Johor Darul Takzim.
TEL: 012-7106867 FAX: 07-598 7551

STOP. LEARN. EXALT.

TRAINERS PROFILE
YIM SZE KHUEN

B. Sc (Electronics Engineering, Pittsburg

State University, United States.)

Certified Six Sigma Black Belt (Seagate

Technology & Flextronics Technology)

A full time continuous improvement management consultant and trainer, Yim works on projects and trains
personnel on Quality Management and Six Sigma Tools and Methodology. His elaborate 18 years background in
the industry in various capacities has given him valuable experience in working with people of different
background and culture. He has served in several well-established organizations and has held various influential
positions in inculcating continuous improvement culture into organizations.
As a Senior Process Engineer in Seagate Technology Sdn Bhd, he was responsible for the process operation of
a section in the clean room department. Later he was selected by management to mobilized Corporate Six Sigma
initiatives which see a change in role from a Process Engineer to a Project Manager (Six Sigma Black Belt). As a
Project Manager he has completed 11 Corporate Business Improvement Projects, these projects centralized on
Quality and Efficiency Improvement. He has worked with Process Engineers, Production, Industrial Engineers
and Maintenance in his projects and this has resulted in a Financial Cost Savings of USD2 million for Seagate
Technology Sdn Bhd.
As a project manager in Flextronics Technology Sdn Bhd he has initiated, led and completed seven Corporate
Business Improvement Projects. These projects centralized on Products Yield Improvement, Inventory
Management, Products Change Over Time and Productivity Improvement projects. This effort has generated in a
Financial Cost Savings of USD6 million for Flextronics Technology Sdn Bhd. He has also conducted Quality
Management tools and Six Sigma Green Belt trainings to all levels of executives in the Plant.
Altogether he obtained two Six Sigma Black Belt certifications and simultaneously has completed a total of 18
Black Belt Projects (Corporate Improvement Projects) with a cumulative cost savings of USD8Million. Coached
and led 30 Green Belts to project completion and Green Belt certification. He is the recipient of the 2002 Seagate
Six Sigma Achievement Recognition Award at Seagate Six Sigma Symposium 2002 in USA.
With his vast industrial, training, coaching, project execution and Six Sigma knowledge and experiences, he will
be able to transfer knowledge and transform trainees into a new level of employees who will be practically ready
for a higher level of challenges to take their organizations towards a new leading competitive edge.
Amongst some of the well established organizations he has worked for were Penang Seagate Technology,
Carsem Semiconductor, Flextronics Technology and Digi Telecommunication.

PROPOSAL NO: TNG-315-12

1768,
Jalan Senai Utama,
81400 Senai,
Johor Darul Takzim.
TEL: 012-7106867 FAX: 07-598 7551

STOP. LEARN. EXALT.

CLIENTS COPY
Project Agreement
V.S. INDUSTRY BERHAD officially confirms that EXALT CONSULTANCY is requested to
provide LEAN MANUFACTURING FOR OPTIMUM PRODUCTION TRAINING for the agreed
sum of RM 7,000 (Ringgit Malaysia Seven Thousand Only).
EXALT CONSULTANCY undertakes upon signing this agreement to provide the services
requested, subject to terms and condition specified in this proposal (TNG-315-12).
Signed for and on behalf of V.S. INDUSTRY BERHAD

Name :..Title...Date.
Signature:

Company seal/Stamp:

Signed for and on behalf of EXALT CONSULTANCY.

Name: K. Puvi Arasu

Title: Operations Manager/Trainer

Date: 29/11/2012

Signature:

PROPOSAL NO: TNG-315-12

1768,
Jalan Senai Utama,
81400 Senai,
Johor Darul Takzim.
TEL: 012-7106867 FAX: 07-598 7551

STOP. LEARN. EXALT.

EXALT CONSULTANCYS COPY

Project Agreement
V.S. INDUSTRY BERHAD officially confirms that EXALT CONSULTANCY is requested to
provide LEAN MANUFACTURING FOR OPTIMUM PRODUCTION TRAINING for the agreed
sum of RM 7,000 (Ringgit Malaysia Seven Thousand Only).
EXALT CONSULTANCY undertakes upon signing this agreement to provide the services
requested, subject to terms and condition specified in this proposal (TNG-315-12).
Signed for and on behalf of V.S. INDUSTRY BERHAD

Name :..Title...Date.
Signature:

Company seal/Stamp:

Signed for and on behalf of EXALT CONSULTANCY.

Name: K. Puvi Arasu

Title: Operations Manager/Trainer

Date: 29/11/2012

Signature:

PROPOSAL NO: TNG-315-12

1768,
Jalan Senai Utama,
81400 Senai,
Johor Darul Takzim.
TEL: 012-7106867 FAX: 07-598 7551