Overview
Learning Outcomes
On completion of The Kaizen Process of Continuous Improvement Program, participants will be able:-
- Problems are identified at source, and resolved.
- Small improvements which are realized can add up to major benefits for the business
- Improvements, which lead to changes in the business quality, cost and delivery of products, mean a greater level of customer satisfaction, and business growth.
- By involving employees in looking at their environment to bring about change, results in improved morale as people begin to find work easier and more enjoyable.
Who Must Attend
- Factory Manager / Production Manager / Executive / Supervisor
- Materials Manager/Executive/Officer
- Warehouse/Store Manager / Executive/ Supervisor
- Production & Materials Planner / Manager
- Purchasing Manager, Executive, Buyer
Course Details
Day 1 :
Module 1: Overview
The Theory behind Kaizen
Since Kaizen is often interpreted differently by the companies that use it. Participants will be introducing to the variations represent the components of Kaizen that become associated with various operational objectives:
- Manufacturing best practices
- Tools for eliminating waste
- Understand and apply the Quality Planning tools.
- Identify and apply the Quality Control tools.
- Identify and utilize Quality Improvement tools
- How to carry out their Process Capability studies.
-
Understand Basic Statistics and Basic Anova.
- Creating standards
- A co-operative environment
- A creative workforce
- Lean manufacturing
b) Theory
- What is Kaizen?
- Why Kaizen?
- What is Waste?
- Value-Added, Lean & Flexible Manufacturing
- People: The Heart and Mind of Kaizen
- The Kaizen Principles
- The Ten Basic Tips for Kaizen Activities
Module 2: Lean Techniques
- 5S
- Single Minute Exchange of Die (SMED) also known as Set-up Reduction :
- Total Productive Maintenance (TPM)
- Standard Work
Day 2:
Module 3: Kaizen Tool
- Pareto Charts:
- Ishikawa (Fishbone) Diagram:
- Histograms
- Check-Sheets
- Five “Why?” Root Cause Analysis: Getting to the root
- Brainstorming and Consensus Decision Making: Facilitation Techniques
- Process Mapping
Module 4: Analysing Charts
- Scatter Plots
- Statistical Process Control
- Gantt Charting:
- Kaizen Event Planning
Methodology
Course methodology includes a combination of Classroom sessions; LCD projector, video presentation as well as work-related application will be used
Course Leader
Mr LEE SOONG YEE
Qualification: B. Eng (US), MIEEE, AMIM, Dip Sc.
Mr LEE, Motorola Six Sigma Green Belt, is extensively involved test development, product engineering, process engineering and handle various manufacturing engineering projects internationally. He comes with 25+ years of experience in semiconductor manufacturing fields and multi-lingual translator.
Professional Qualifications:
- MIEEE (member of Institute of Electrical Electronic Engineer, USA)
- AMIM (Associate Malaysia Institute of Management)
- Bachelor Engineering (USA)
- Certificate Chinese Education (Taiwan)
- Diploma in Science (Malaysia)
Achievements:
NATIONAL SEMICONDUCTOR
- Started as a Test & Product Engineer and built the first wafer bump process in National Semiconductor factory in Malaysia.
- Leads various productivity project and process improvement project in the factory.
- Worked in National Semiconductor Malaysia, Singapore and Santa Clara factories for 9 years till Year-2002 as the Senior Engineer.
MOTOROLA / FREESCARE SEMICONDUCTOR
- In 2002, worked in Motorola Semiconductor Kuala Lumpur (currently known as Freescale Semiconductor Malaysia (M) Sdn. Bhd.) as Senior Test Engineer
- 2004, Promoted to Senior Staff Engineer to engage extensively in process, yield and productivity improvement.
- Successfully stabilize one of the most important platforms in the Motorola Kuala Lumpur factory.
- Speedy promotion to head the NPI (New Product Introduction) department to manage a group of product and test engineers in the factory for all new products introduction activities for Motorola Semiconductor Kuala Lumpur.
- Champion and develop GAGE RR Project
- Conducts ATE and tester trainings in Motorola and many trainings in Freescale factories
- 2007- Head of Test-Engineering team for Freescale Semiconductor (Motorola spun off),
- Lead a group of system engineers, ATE application engineers and system admin team
- In charge of various project across in Malaysia, various subcond houses, USA factories and China factories.
IRIS CORPORATION
- 2010- Setup R&D department and in charge of continuous process improvement
- Spearhead the Change Management board in the organization from 2010- 2012.
TRAININGS CONDUCTED:
- Certified trainer Malaysia government's HRDC (Human Resource Development Council) or PSMB since Dec 2012.
- Clocked in more than 1000 hours of technical trainings for engineering manager, engineers from various fields, technician, supervisor and technical specialist since 1997.
Course conducted includes since 1997:
- FMEA
- DMAIC
- 8D Methodology
- Test system
- Digital test methodology
- Analog testing
- Teradyne A575 system
- Serial and parallel communication system
- Daymarc Handler multi site testing in high volume manufacturing,
- Operation Amplifier testing theory, Compact Programming,
- C++ programming for beginners
- MCT tester theory and application,
- One Test Strategy Methodology for productivity and cost saving in high volume manufacturing,
- GRR
- Source of variation,
- Binary Coded Decimal Communication Protocol in handler, A360 tester programming theory and hardware,
- Teradyne J273 tester hardware and programming methodology,
- Multi Site testing,
- Hot Chuck theory and Procedures for wafer probing,
- Teradyne tester analog hardware oscillation and debugging,
- IMAGE programming, Microcontroller and Microprocessor test time reduction in final testing, J750 test time reduction via system methodology,
- J750 eFrame tester oscillation solution and multi site testing, J750 IGXL 3.40.09 Theory and Conversion, New Product Introduction NPI Maturity Matrix,
- Freescale files transfer system for subcond house KESM and TTM,
- Gage Repeatability and Reproducibility application for engineering,
- Problem Solving tools and Ichikawa diagram,
- Manufacturing best practices,
- Change Management Principles, Maverick Theory and statistical control, Engineering investment and ROI calculation,
- Manufacturing Ground rules, OEE (Overall Equipment Efficiency) Calculation,
- ESD Theory
- Lean Manufacturing Initiative and Theory.
Other involvements
Mr Lee is also passionate about sharing his knowledge and skills and lectures in many tertiary institutions throughout Asia Pacific.
He is the technical supervisor for the:
- post-graduate master degree program students’ for MARA university students in Malaysia.
- undergraduates for final year thesis of Monash University, Inti College, KDU, Nottingham University, government SHRDC, as well as various local universities in Malaysia.
To contact SY Lee, please feel free to email us at info@itrainingexpert.com or call +603 8074 9056 | +6012 6869 628
Or
We have a faculty of specialist and can cater to your organisation's different levels and specific needs.
For training and advisory services, feel free to contact us at info@itrainingexpert.com or call us at +603 8082 3707 | +603 8074 9056 | +6012 6869 628 | +6018 2175 123
Testimonies
“The trainer has good creativity thinking and able to give examples for better understanding. ” Law Siew Kiong, Shell MDS (M) Sdn Berhad.
“ Trainer is knowledgeable and good at delivering the 8D Problem Solving process information clearly .” Munirah binti Daud, Giesecke & Devrient Malaysia Sdn Bhd
Investment
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