STOP. LEARN. EXALT.

1768,

Jalan Senai Utama, 81400 Senai,

Johor Darul Takzim.

PROPOSAL NO: TNG-315-12 TEL: 012-7106867 FAX: 07-598 7551

PROPOSAL TO

V.S. INDUSTRY BERHAD

FOR

LEAN MANUFACTURING

FOR OPTIMUM PRODUCTION

TRAINING

STOP. LEARN. EXALT.

1768,

Jalan Senai Utama, 81400 Senai,

Johor Darul Takzim.

PROPOSAL NO: TNG-315-12 TEL: 012-7106867 FAX: 07-598 7551

(1) INTRODUCTION

(2) TRAINING COURSE OUTLINE &

TRAINER’S PROFILE

(3) PROJECT AGREEMENT

CONTENTS

STOP. LEARN. EXALT.

1768,

Jalan Senai Utama, 81400 Senai,

Johor Darul Takzim.

PROPOSAL NO: TNG-315-12 TEL: 012-7106867 FAX: 07-598 7551

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.

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

2. Training Course Outlines & Trainer’s Profile

1. Introduction

STOP. LEARN. EXALT.

1768,

Jalan Senai Utama, 81400 Senai,

Johor Darul Takzim.

PROPOSAL NO: TNG-315-12 TEL: 012-7106867 FAX: 07-598 7551

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 it’s 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 Customer’s 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 equipment’s 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.

STOP. LEARN. EXALT.

1768,

Jalan Senai Utama, 81400 Senai,

Johor Darul Takzim.

PROPOSAL NO: TNG-315-12 TEL: 012-7106867 FAX: 07-598 7551

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

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

3. 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

STOP. LEARN. EXALT.

1768,

Jalan Senai Utama, 81400 Senai,

Johor Darul Takzim.

PROPOSAL NO: TNG-315-12 TEL: 012-7106867 FAX: 07-598 7551

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…

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1768,

Jalan Senai Utama, 81400 Senai,

Johor Darul Takzim.

PROPOSAL NO: TNG-315-12 TEL: 012-7106867 FAX: 07-598 7551

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… 6. 9 Keys to lean development

Customer Focus

Leadership and Strategic Planning

Organization Architecture

Lean Supply Chain

Information Architecture

Improvement Technology

Production Management

Equipment/Process Management

Product/Process Engineering 7. Benefits of lean manufacturing

Material Handling Benefits

Inventory Benefits

Quality Benefits

People Benefits

Customer Benefits 8. Techniques and tools of lean manufacturing

Value Mapping

SMED (Single Minute Exchange of Dies)

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1768,

Jalan Senai Utama, 81400 Senai,

Johor Darul Takzim.

PROPOSAL NO: TNG-315-12 TEL: 012-7106867 FAX: 07-598 7551

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 9. 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.

STOP. LEARN. EXALT.

1768,

Jalan Senai Utama, 81400 Senai,

Johor Darul Takzim.

PROPOSAL NO: TNG-315-12 TEL: 012-7106867 FAX: 07-598 7551

TRAINER’S PROFILE

YIM SZE KHUEN

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.

B. Sc (Electronics Engineering, Pittsburg State University, United States.)

Certified Six Sigma Black Belt (Seagate Technology & Flextronics Technology)

STOP. LEARN. EXALT.

1768,

Jalan Senai Utama, 81400 Senai,

Johor Darul Takzim.

PROPOSAL NO: TNG-315-12 TEL: 012-7106867 FAX: 07-598 7551

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:

Project Agreement

CLIENT’S COPY

STOP. LEARN. EXALT.

1768,

Jalan Senai Utama, 81400 Senai,

Johor Darul Takzim.

PROPOSAL NO: TNG-315-12 TEL: 012-7106867 FAX: 07-598 7551

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:

Project Agreement

EXALT CONSULTANCY’S COPY