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KAIZEN Process of Continuous Improvement

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Description

KAIZEN is one of the famous Japanese philosophies on continual improvement. Kaizen means improvement, which is ongoing and involve everyone. 

The word of "Kaizen" derived from Japanese dictionary, which means continuous improvement. In Japan continuous improvement techniques applied in Toyota and Canon companies to measures for implementing continuous improvement. Kaizen has been applied in various sectors such as healthcare, government, manufacturing and etc. The objective of implementing is reducing waste, improving productivity and safety of the company. All employees in organization from upper management to lower level to work as a team and everyone involved with making improvement.

To train the participants in continuous improvement and proposal system of Kaizen in order for them to contribute in the company’s continuous improvement program. 

Top Management, Managers, Executives, Engineers, Supervisors, Technicians etc.

SECTION 1: THE CONCEPT OF KAIZEN

  • Terms & Definition
  • Introduction to KAIZEN & Key Elements of KAIZEN
  • Gemba KAIZEN
  • KAIZEN and the Suggestion System
  • Process-oriented Management vs Result-oriented Management

SECTION 2: KAIZEN VS INNOVATION

  • Differences Between Maintenance, KAIZEN & Innovation
  • KAIZEN vs Innovation
  • KAIZEN and Measurement
  • The Roles of each Hierarchy KAIZEN Involvement
  • Daily improvement and 10x breakthrough
  • The 3M strategies on MUDA,MURI, MURA

SECTION 3: RELATIONSHIP BETWEEN KAIZEN AND TOYOTA PRODUCTION SYSTEM/ISO 9001 IMPLEMENTATION

  • Japanese vs Western Approaches
  • Toyota Production System
  • Dangerous Waste
  • Value Stream Mapping
  • 5S Housekeeping Culture
  • KAIZEN cultures
  • KAIZEN Gemba actual implementation

SECTION 4: THE PRACTICE

  • 3 Main Segments for KAIZEN Implementation
  • Management-oriented KAIZEN
  • Group-oriented KAIZEN
  • Individual-oriented KAIZEN
  • Group Exercise
  • 7 QC Tools
  • Sample of Action Plan
  • Management roles in KAIZEN

SECTION 5: GETTING READY

  • 4 Stages of Implementation (Training, Planning, Implementing & Auditing)
  • Some Tips to Get Started
  • The Wet Blanket List

SECTION 6: WORKSHOP

KAIZEN STEP-BY-STEP DEPLOYMENT

  • Data Collection on Process Study
  • Identify Process Flow and Process Elements and Layout
  • Time and Motion Study
  • Identify Value Added and Non-Value Added Elements
  • Standard Work
  • Complete Housekeeping (3S) Improvement
  • Sustaining KAIZEN

Interactive lectures, discussions, case studies, progressive assessments and presentations.

MEGAT RIDZUAN 

Safety, Health, Environment & Risk Management Specialist
Master's Degree in Manufacturing System Engineering | Bachelor's Degree in Mechanical Engineering

PROFILE SUMMARY

Megat is a highly experienced Safety, Health, Environment and Risk Management (SHERM) professional and corporate trainer with over two decades of hands-on industry experience spanning the automotive, food and beverage, and oil and gas sectors. Having worked with multinational corporations including DENSO, Nestlé and F&N Dairies, Megat brings a wealth of practical knowledge, technical expertise and cross-industry insights to every training and advisory engagement.

His career is distinguished by a proven track record in establishing world-class quality, safety, health and environmental management systems, leading organisations to achieve internationally recognised certifications, and developing high-impact training programmes for both corporate and government clients.

CORPORATE EXPERIENCE

DENSO (M) Sdn Bhd (2001 – 2007)
QA/QC Engineer & Safety, Health and Environment Officer

Megat began his professional career at DENSO Malaysia, a leading Japanese automotive components manufacturer, where he was instrumental in establishing and implementing a comprehensive suite of Quality, Safety, Health and Environmental programmes. Key contributions include:

  • Developed and implemented critical quality programmes including Calibration Methodology, Mechanical Testing & Reliability, 7 QC Tools, Statistical Process Control and Problem-Solving frameworks
  • Established safety and environmental programmes including Emergency Response Planning, Fire Fighting, Chemical Safety, Lock-Out Tag-Out (LOTO), Hearing Conservation, Permit to Work, Contractor Safety Passport and the Kiken Yochi (Hazard Prediction) Programme
  • Managed Schedule Waste and Industrial Effluent programmes in compliance with regulatory requirements
  • Led the organisation to achieve ISO/TS 16949:2002 certification (2003) and the prestigious Selangor Environmental Awards (2007)

Nestlé (M) Sdn Bhd (2007 – 2009)
Safety, Health & Environmental Manager

Megat was recruited by Nestlé Malaysia, a globally renowned Switzerland-based food and beverage corporation, to lead their Safety, Health and Environmental function. Key contributions include:

  • Oversaw all SHE programmes, activities and compliance initiatives across the organisation
  • Successfully led the company to achieve Integrated Management System (IMS) Certification comprising:
    • ISO 22000:2005 — Food Safety Management System
    • ISO 14001:2004 — Environmental Management System
    • OHSAS 18001:2007 — Occupational Health & Safety Management System

F&N Dairies (M) Sdn Bhd (2009 – 2011)
Safety, Health & Environmental Manager

Megat joined Fraser & Neave (F&N) Dairies Malaysia, a Singapore-based multinational dairy manufacturer, where he managed the full spectrum of the factory's Safety, Health and Environmental programmes, operational activities and legal compliance requirements.

TRAINING & ADVISORY PRACTICE (2011 – Present)
Independent Trainer & SHE Consultant

Since 2011, Megat has been operating as a full-time corporate trainer and SHE consultant, providing professional training and advisory services to organisations in the oil and gas sector and beyond. Key engagements include:

  • Provided strategic SHE advisory services to oil and gas companies including SVP Petroleum and SEM Inspection, advising Plant Managing Directors, Plant Managers and key employees on Safety, Health and Environmental compliance and best practices
  • Engaged by the National Institute of Occupational Safety and Health (NIOSH) to conduct training for several accredited programmes including:
    • NIOSH Safety & Health Officer Programme
    • NIOSH Talk Series
    • Contractor Safety Passport System
    • Syabas NIOSH Safety Passport
    • NIOSH Nestlé Passport System

AREAS OF TRAINING EXPERTISE

  • Occupational Safety & Health (OSH) Management
  • Environmental Management & Sustainability
  • Quality Management Systems (ISO/TS 16949, ISO 14001, OHSAS 18001, ISO 22000)
  • Hazard Identification, Risk Assessment & Risk Control (HIRARC)
  • Emergency Response Planning & Fire Safety
  • Chemical Safety & Hazardous Materials Management
  • Permit to Work & Lock-Out Tag-Out (LOTO) Systems
  • Contractor Safety Management
  • Statistical Process Control & 7 QC Tools
  • Problem Solving & Root Cause Analysis

SELECTED INDUSTRY EXPERIENCE

  • Automotive Manufacturing — DENSO (M) Sdn Bhd
  • Food & Beverage Manufacturing — Nestlé (M) Sdn Bhd | F&N Dairies (M) Sdn Bhd
  • Oil & Gas — SVP Petroleum | SEM Inspection
  • Government & Statutory Bodies — NIOSH Malaysia


Or
We have a faculty of specialists who 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

Normal Fee Early Bird Group Fee
Sign up 1 pax Sign up 1 pax Sign up 3 pax or more
Pay 1 day(s) before course starts Pay 14 day(s) before course starts Pay 14 day(s) before course starts
MYR 3490 per pax MYR 2890 per pax MYR 2790 per pax
USD 1990 per pax USD 1490 per pax USD 1390 per pax

(Fee inclusive of Training Materials & Certificate of Achievement. Fee is NOT INCLUSIVE OF 6% SST.)

Upon successful completion of this program, you will receive a Certificate of Achievement.

Payment mode:

1. ONLINE PAYMENT by Credit card: You can opt to register and pay online with our latest payment integration system through our website.

2. BANK IN CHEQUE
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Courier your cheque payment to our Finance HQ.

*Note that we DO NOT take any payments during the event.
3. BANK IN CASH:You can also pay by cash through bank-in our company bank account.
4. Telegraphic Transfer- You can also opt to use GIRO or telegraphic transfer of payment via international banks.

We'd happy to help.
Feel free to talk to us today, however most suitable for you.
Mobile call/ whatsapp: +6012 6869 628 | +6018 2175 123
Office: +603 8074 9056
Email: info@itrainingexpert.com
Website: www.itrainingexpert.com

USD 1990
Group Price USD 1390
3+ pax discount
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