advanced manufacturing consultancy sdn. bhd. lean master program

Advanced Manufacturing Consultancy Sdn. Bhd.Advanced Manufacturing Consultancy Sdn. Bhd.

Lean MasterLean MasterProgramProgram

Manufacturing & business solutions towards increased profitability

Objectives & Contents

Brief background of AMCBrief background of AMC

Lean & TOC in a nut-shellLean & TOC in a nut-shell

AMC ServicesAMC Services

Details of the Lean Master Certification ProgramDetails of the Lean Master Certification Program

Benefits & Credentials of the Lean Master ProgramBenefits & Credentials of the Lean Master Program


Brief Background of AMC

Advanced Manufacturing Consultancy (AMC) is a Manufacturing Advanced Manufacturing Consultancy (AMC) is a Manufacturing Consulting company, founded and registered in Malaysia in 2001Consulting company, founded and registered in Malaysia in 2001

The company is founded by former Seagate Technology’s internal The company is founded by former Seagate Technology’s internal Corporate Lean Consultants. They had extensive exposure in Lean Corporate Lean Consultants. They had extensive exposure in Lean Deployment within Seagate and led the Deployment within Seagate and led the Supplier Lean Academy in AsiaSupplier Lean Academy in Asia. . Having accomplished great savings for Seagate & its suppliers they Having accomplished great savings for Seagate & its suppliers they formed AMC as a leading service provider in Lean Manufacturing formed AMC as a leading service provider in Lean Manufacturing consulting & training in Asia and have currently expanded to wider areas consulting & training in Asia and have currently expanded to wider areas of serviceof service


Lean & TOC in a nut-shell: What is Lean Manufacturing

Lean is a leading edge manufacturing technology which aims to identify Lean is a leading edge manufacturing technology which aims to identify and eliminate or reduce “Lean Wastes” (non value added activities) in and eliminate or reduce “Lean Wastes” (non value added activities) in any manufacturing environment (regardless of size or industry) by using any manufacturing environment (regardless of size or industry) by using systematic Lean Tools. systematic Lean Tools.

The “Lean Wastes” are :The “Lean Wastes” are :

Excess InventoryExcess Inventory

Maintaining excess inventory of raw materials, parts in process, or finished goods OverproductionOverproduction

Producing more than is needed before it is needed MotionMotion

Any wasted motion to pick up parts or stack parts TransportationTransportation

Wasted effort to transport materials, parts, or finished goods into or out of storage WaitingWaiting

Material awaiting to be processed or to be transported Over processingOver processing

Doing more work than is necessary CorrectionCorrection

Repair or Rework Unutilized Human ResourcesUnutilized Human Resources

Not using operators to their maximum ability


Lean & TOC in a nut-shell: What Is The TOC

The Theory of Constraints is a focused and proven approach of The Theory of Constraints is a focused and proven approach of identifying what limits (constraints) a system from achieving it’s profit identifying what limits (constraints) a system from achieving it’s profit goals or continuously achieving higher goals and exploiting these goals or continuously achieving higher goals and exploiting these constraints in order to achieve constraints in order to achieve quantum gains within a very short period of quantum gains within a very short period of timetime

Advanced Manufacturing Consultancy approaches Manufacturing Advanced Manufacturing Consultancy approaches Manufacturing Solutions by using the Theory of Constraints to identify System Solutions by using the Theory of Constraints to identify System Limitations (Constraints) and using Lean Tools to eliminate Waste at the Limitations (Constraints) and using Lean Tools to eliminate Waste at the constraintconstraint


SolutionsSolutionsForFor

Increased Increased ProfitabilityProfitability

SolutionsSolutionsForFor

Increased Increased ProfitabilityProfitability

Services Offered by AMC

Lean ConsultingLean ConsultingAssessments & Opportunity

identificationLean Diagnostics to identify Waste

Factory Audit and scoringEngaged with client in Lean ProjectsSupplier Lean initiatives – speeding

time to respond

Constraint BustingConstraint BustingIdentifying System Constraints &

BottlenecksIncreasing bottleneck Capacities

withLow Cost or No Cost Solutions

Training & Education Training & Education Lean Tools Training

Lean Master Certification Program

Public SeminarsExecutive Boot-camps

Short CoursesSix Sigma training


LEAN ASSESSMENT CHART

1

2

3

4

5

6

7

8

9

10THEORY OF CONSTRAINTS

LEAN APPROACH

PERFORMANCE MEASUREMENT

5S & VISUAL SYSTEMS

STANDARDISED WORK

QUICK SET-UPS

ERROR PROOFING

INVENTORY MANAGEMENT

TOTAL PRODUCTIVE MAINTENANCE

PROJECTS & CHANGE LEADERSHIP

Key Services Description

Lean AssessmentsLean AssessmentsDiagnostic Assessment and Opportunity IdentificationDiagnostic Assessment and Opportunity Identification

This service is performed typically over a period of 2 to 3 days by 2 This service is performed typically over a period of 2 to 3 days by 2 consultants. The clients level of Lean deployment and opportunities for consultants. The clients level of Lean deployment and opportunities for improvement is assessedimprovement is assessed



Lean Consulting-Constraint BustingLean Consulting-Constraint Busting

Consultants work with clients to identify and improve existing bottleneck Consultants work with clients to identify and improve existing bottleneck performances to meet increased demands. Projects frequently lead to performances to meet increased demands. Projects frequently lead to huge capital avoidance for clientshuge capital avoidance for clients

Daily Laser weld performance trend

0

5000

10000

15000

20000

25000

30000

35000

40000

45000

08/0

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08/0

8/2

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08/1

5/2

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08/2

2/2

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08/2

9/2

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09/0

5/2

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09/1

2/2

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09/1

9/2

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10/1

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7/2

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10/2

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Pieces

Da

y

Total Commit Linear (Total)

Implemented Actions:1. Full Time MH to feed parts2. Communication to operators3. Reduced shift end braek from 10 to 5 mins

Cross trained 4 operators per shift to run during break hours

-Established Kanban-Batch Oven Loading-Increased Stator Assy. Capacity

Sunday Running 50%

1 New MachineAdded(Running on 22-9 onwards)

BEFORELEAN

AFTER LEAN


Lean EducationLean EducationLean Education involves the transfer of hands on knowledge on theory Lean Education involves the transfer of hands on knowledge on theory and application of all the Tools in the Lean Toolbox. This is done and application of all the Tools in the Lean Toolbox. This is done through in-house or public training sessions. The approach taken is through in-house or public training sessions. The approach taken is one of Learn-Do-Mentoring. Training includes:one of Learn-Do-Mentoring. Training includes: Two Day Value Stream Mapping sessionTwo Day Value Stream Mapping session 5-14 day short courses5-14 day short courses One day Theory of Constraint Boot-campsOne day Theory of Constraint Boot-camps Two day Executive Boot-camps (TOC, Lean Overview, Value Stream mapping & Two day Executive Boot-camps (TOC, Lean Overview, Value Stream mapping &

Change Leadership)Change Leadership) Lean Master Certification ProgramLean Master Certification Program



THE LEAN MASTERTHE LEAN MASTERCERTIFICATIONCERTIFICATION

PROGRAMPROGRAM


The Lean Master Program Outline

Total 5 WavesTotal 5 WavesSpread Over 5-Spread Over 5-

6 Months6 Months

Taught byQualified Lean

MastersWith Long Industry Exposure

Delivered Through• Class Room

Theory• Simulations•Diagnostics• Shop Floor

Activities• Case Studies

• Projects on Real Problems




6 Months6 Months







The 5 Waves Structure

• There are 4 Waves of 4 Days each

• The Final Wave is graduating Case Study Wave of 2 Days

• Total of 18 Days of Training & Development




6 Months6 Months







Hands-On Approach

• Candidates are exposed to:

• 3 Whole day class Room Simulations & several more half day simulations

• 3 Video movies

• Shop Floor exercises for all major tools taught

• 3 Real Projects needs to be completed by each candidate




6 Months6 Months







The Trainers

• They are Qualified Lean Masters

• They have Industry Exposure in Manufacturing Environment for more than 15 years

• They have trained and consulted small as well as Fortune 50 companies


The Lean Master

The Lean Master Graduate Will Be Trained To Become:The Lean Master Graduate Will Be Trained To Become:

Lean Leaders of Operational Excellence

Lean Leaders of Operational Excellence

Lean Practitioners who can Diagnose & Solve problemsLean Practitioners who can Diagnose & Solve problems

Effective Organizational Change Agents

Effective Organizational Change Agents

Lean Consultants who can improve manufacturing profitability

Lean Consultants who can improve manufacturing profitability


Wave OneLean Overview

Change Management5 S

Need to Need to completecomplete1 project 1 project before next before next WaveWave

4 – 5 4 – 5 Weeks Weeks LaterLater

4 – 5 4 – 5 Weeks Weeks LaterLater

Need to Need to completecomplete1 project 1 project before next before next WaveWave

The program is taught in a The program is taught in a Learn-Do-Mentor Learn-Do-Mentor approachapproach

Wave TwoSetup Time Reduction

Visual ManagementWork Standardization

Wave ThreeError Proofing

Overall Eqt. EffectivenessTotal Prod. Maintenance

The Training Approach


The Course Contents

Wave 1 - The Compass WaveWave 1 - The Compass WaveLean OverviewLean Overview This offers a birds-eye view of the Tools of Lean Manufacturing and their effect This offers a birds-eye view of the Tools of Lean Manufacturing and their effect It is delivered through a one-day highly interactive simulation using LegoIt is delivered through a one-day highly interactive simulation using Lego

Value Stream MappingValue Stream Mapping It is a Diagnostic exercise which helps map what adds value and what is not It is a Diagnostic exercise which helps map what adds value and what is not

adding value in the whole systemadding value in the whole system Identifies opportunities for Lean improvementIdentifies opportunities for Lean improvement Team is made to draw clients actual value stream mapTeam is made to draw clients actual value stream map

Lean Thinking ProcessLean Thinking Process Theory and thought process of Lean Manufacturing and the Theory of ConstraintsTheory and thought process of Lean Manufacturing and the Theory of Constraints


The Course Contents

Wave 1 - The Compass WaveWave 1 - The Compass Wave

Change Management- Leading Change & Communication Change Management- Leading Change & Communication StrategiesStrategies A detail look into why any organizational change fails and how to Lead A detail look into why any organizational change fails and how to Lead

effective changeeffective change Methods of stakeholder communication Methods of stakeholder communication The Who Moved My Cheese video is showedThe Who Moved My Cheese video is showed

Shop Floor Management - 5S Shop Floor Management - 5S The basics of Lean starts with an organized shop-floorThe basics of Lean starts with an organized shop-floor 5S methods are taught and shop-floor red-tagging activity is carried out5S methods are taught and shop-floor red-tagging activity is carried out

Lean Project Management and requirementsLean Project Management and requirements Projects are identified for Wave 1Projects are identified for Wave 1


The Course Contents

Wave 2 Wave 2

Wave 1 Projects presentation & Review Wave 1 Projects presentation & Review Review of actual projects completed by Lean Master candidates between Review of actual projects completed by Lean Master candidates between

Wave 1 & 2Wave 1 & 2

Change Management - Handling Resistance & Practical Filed Change Management - Handling Resistance & Practical Filed GuideGuide Covers difference types of resistance people pose to change and Covers difference types of resistance people pose to change and

methods of handling thesemethods of handling these Practical assessment of clients change adaptability and strategies for Practical assessment of clients change adaptability and strategies for

effective Lean deploymenteffective Lean deployment


The Course Contents

Wave 2 Wave 2

Shop Floor Management - Visual Systems & Standardized WorkShop Floor Management - Visual Systems & Standardized Work Working towards a Visual factory where one will be able to tell at a glance Working towards a Visual factory where one will be able to tell at a glance

“what is going on” and “what is needed’ in the shop-floor“what is going on” and “what is needed’ in the shop-floor Standardized work covers methods and strategies of repeatability in Standardized work covers methods and strategies of repeatability in

processes and shop-floor activities. It also covers importance and features processes and shop-floor activities. It also covers importance and features of an effective SOP of an effective SOP

Setup Time ReductionSetup Time Reduction This is a powerful tool used to reduce change-over time and setup This is a powerful tool used to reduce change-over time and setup

activities such as PM, Daily Cleaning etc.activities such as PM, Daily Cleaning etc. The module is taught with an exciting car tyre changing exercise and The module is taught with an exciting car tyre changing exercise and

video shooting before doing actual shop-floor activityvideo shooting before doing actual shop-floor activity


The Course Contents

Wave 3Wave 3

Wave 2 Projects presentation & ReviewWave 2 Projects presentation & Review Review of actual projects completed by Lean Master candidates between Review of actual projects completed by Lean Master candidates between


Error ProofingError Proofing A detail study of methods and strategies of mistake proofingA detail study of methods and strategies of mistake proofing Covers methods such as Red-Flag conditions, Fish Bone analysis and Covers methods such as Red-Flag conditions, Fish Bone analysis and

detail problem solving strategiesdetail problem solving strategies

Lean Performance MetricsLean Performance Metrics A specific set of measurements which are a driving force towards speed, A specific set of measurements which are a driving force towards speed,

flexibility and predictability in an organizationflexibility and predictability in an organization Covers Measurements such as Manufacturing Cycle Time (MCT), Overall Covers Measurements such as Manufacturing Cycle Time (MCT), Overall

Equipment Effectiveness (OEE), Dock to Dock Time (DTD), Throughput Equipment Effectiveness (OEE), Dock to Dock Time (DTD), Throughput Metrics etc.Metrics etc.


The Course Contents

Wave 3Wave 3

Total Productive MaintenanceTotal Productive Maintenance A structured approach to maintaining equipment to enable stable A structured approach to maintaining equipment to enable stable

processesprocesses Includes Machine measurements such as OEE, MTBA, MTBR etcIncludes Machine measurements such as OEE, MTBA, MTBR etc Addresses importance and strategies of using Autonomous Maintenance Addresses importance and strategies of using Autonomous Maintenance

(operator involvement) in improving equipment OEE(operator involvement) in improving equipment OEE

Case StudiesCase Studies Real factory problems are submitted in the form of case studies to brush Real factory problems are submitted in the form of case studies to brush

problem solving skills in the candidatesproblem solving skills in the candidates Case studies will cover each of the key Lean tools taughtCase studies will cover each of the key Lean tools taught


The Course Contents

Wave 4Wave 4

Wave 3 Projects Presentation & ReviewWave 3 Projects Presentation & Review Review of actual projects completed by Lean Master candidates between Review of actual projects completed by Lean Master candidates between


Theory of Constraints & Drum-Buffer-Rope Theory of Constraints & Drum-Buffer-Rope The principles of bottleneck management and the application of the Drum The principles of bottleneck management and the application of the Drum

Buffer Rope material managementconcept to optimize bottlenecksBuffer Rope material managementconcept to optimize bottlenecks Theory of the TOC thought processTheory of the TOC thought process

The Goal MovieThe Goal Movie The Goal Movie is a world renowned movie presentation of TOC concepts The Goal Movie is a world renowned movie presentation of TOC concepts

and application of the Theory of Constraints in a real factory sceneand application of the Theory of Constraints in a real factory scene


The Course Contents

Wave 4Wave 4

Material Management & Kanban SystemsMaterial Management & Kanban Systems Different Types and methods of Material Control and Pull System are Different Types and methods of Material Control and Pull System are

discussed and taughtdiscussed and taught Topics include: KANBAN Types, KANBAN Quantities and formulas etc.Topics include: KANBAN Types, KANBAN Quantities and formulas etc.

Lean DiagnosticsLean Diagnostics Understanding how to assess a plant, identify opportunities and decide on Understanding how to assess a plant, identify opportunities and decide on

the specific tools to be appliedthe specific tools to be applied


The Course Contents

Wave 4Wave 4

The Lean RoadmapThe Lean Roadmap Candidates are given the right approach in deploying Lean and Candidates are given the right approach in deploying Lean and

proliferating it throughout a plant in stagesproliferating it throughout a plant in stages

IT ToolsIT Tools a Discussion on what an IT system should provide in order to support a a Discussion on what an IT system should provide in order to support a

Lean & TOC factoryLean & TOC factory Discusses some of the drawbacks and suggestion on current IT solutions Discusses some of the drawbacks and suggestion on current IT solutions

such as MRPII, ERP etc.such as MRPII, ERP etc.

Case Studies & TestCase Studies & Test Candidates are required to pass test on the various modules taught from Candidates are required to pass test on the various modules taught from

Wave 1 - Wave 4Wave 1 - Wave 4


The Course Contents

Wave 5 - The Graduation WaveWave 5 - The Graduation Wave

High Level Case Study and Problem solvingHigh Level Case Study and Problem solving A high level case study which requires extensive diagnostic abilities and A high level case study which requires extensive diagnostic abilities and

team collaboration is presented to candidatesteam collaboration is presented to candidates Candidates work in small group teams (about 3 or 4 members) in solving Candidates work in small group teams (about 3 or 4 members) in solving

this Harvard Business School Level case study which is based on actual this Harvard Business School Level case study which is based on actual factory problemsfactory problems

Group PresentationsGroup Presentations Group presentation of the Case StudyGroup presentation of the Case Study

Graduation CeremonyGraduation Ceremony Awarding of certificatesAwarding of certificates


Requirements for graduation

Each candidate must fulfill following requirements in order to Each candidate must fulfill following requirements in order to graduate as a Lean Mastergraduate as a Lean Master Must have attended and had active participation in all 5 Waves of the Must have attended and had active participation in all 5 Waves of the

programprogram Active participation and presentation of case studies given during waves 3 Active participation and presentation of case studies given during waves 3

& 4& 4 Complete at least 3 projects and must have shown a real improvement Complete at least 3 projects and must have shown a real improvement

trend acknowledged by trainers and candidate’s management teamtrend acknowledged by trainers and candidate’s management team Passed the comprehensive Test in wave 4Passed the comprehensive Test in wave 4


The Co-Pilot

Each Lean Master candidate is entitled to bring along one Each Lean Master candidate is entitled to bring along one assistant (referred to as co-pilot) to the wave. The co-pilot may assistant (referred to as co-pilot) to the wave. The co-pilot may attend and assist either in a whole wave or part of a waveattend and assist either in a whole wave or part of a wave If a co-pilot attends only a certain topic in a wave the Lean Master If a co-pilot attends only a certain topic in a wave the Lean Master

candidate can bring another co-pilot for remaining topics in that Wavecandidate can bring another co-pilot for remaining topics in that Wave

In Summary: A Lean Master can have 1 co-pilot with him (need In Summary: A Lean Master can have 1 co-pilot with him (need not be same person) on each Topic of the trainingnot be same person) on each Topic of the training

A co-pilot who attends at least one whole topic receives a co-A co-pilot who attends at least one whole topic receives a co-pilot certificatepilot certificate


Executives & Sponsors

Executives and sponsors will be invited to sit in selected Executives and sponsors will be invited to sit in selected sessions throughout the Lean Master trainingsessions throughout the Lean Master training

The topics selected for Executive participation is to:The topics selected for Executive participation is to: Expose executives to concepts of Lean & TOCExpose executives to concepts of Lean & TOC Understand diagnostic findings of candidates and approve of area of Understand diagnostic findings of candidates and approve of area of

focus for improvementfocus for improvement Show sponsorship in Leading the Change processShow sponsorship in Leading the Change process Be familiar with the Performance Measurements used by Lean MastersBe familiar with the Performance Measurements used by Lean Masters

Topics which executives should participateLean Overview, Theory of Constraints, Performance Metrics,Change Leadership, Value Stream Mapping & Lean Roadmap


The Lean Master Program Structure

Lean Master CandidatesAttend 5 Waves

& Complete 3 Projects Each

Lean Master CandidatesAttend 5 Waves

& Complete 3 Projects Each

Co-PilotsAttend Specific Topics

&Assist in Projects

Co-PilotsAttend Specific Topics

&Assist in Projects

Executives Attend ImportantSelected Topics

Executives Attend ImportantSelected Topics

The client gets 7-10 candidates trained as internal Lean Consultants with all the skills necessary to Diagnose, Strategize, Improve & deploy Lean factory-wide

A big group of second level assistants may attend 1, 2 or up to 4 waves to be trained in specific topics of interest or importance in their area. Co-Pilots are similar in level in Lean to the Green Belts of Six Sigma

Executives such as Plant Manager, Senior Directors, Department Heads etc. will be exposed to important aspects of Lean Concepts and will be able to participate in key diagnostic findings and approve improvement focus for the team


The Lean Master Program Structure

A Value Stream Map OfClient Site

Created at Wave 1

A Value Stream Map OfClient Site

Created at Wave 1

Projects Are Based OnActual Issues In Client’s

Shop-Floor

Projects Are Based OnActual Issues In Client’s

Shop-Floor

Lean Roadmap IsCreated In Wave 4

To Guide Lean Proliferation

Lean Roadmap IsCreated In Wave 4

To Guide Lean Proliferation

The client’s site VSM shows actual Value Adds & Non Value Adds. Actions and Lean Projects will be focused on tapping opportunities found in this VSM

All projects will be based on real shop-floor problems. The client will start to reap benefit of the Lean Master program right after Wave 1

Executives & Candidates together are involved in creating a Future State Value Stream Map and a road map for full Lean deployment. A structure of Lean Organization within the client’s factory could be formed here with the guidance of AMC consultants

The Lean Master program The Lean Master program sets the framework for sets the framework for the development of a the development of a

complete Lean Academy complete Lean Academy in an organizationin an organization

In Conclusion-A Complete Development Program


BENEFITS BENEFITS


Benefits

Lean Master Program trains a set of internal Lean Consultants Lean Master Program trains a set of internal Lean Consultants with the knowledge st to:with the knowledge st to: Diagnose Factory problems Diagnose Factory problems Strategically focus Lean Improvements in areas which matter mostStrategically focus Lean Improvements in areas which matter most Have skills to actually use the Lean Tools to solve problemsHave skills to actually use the Lean Tools to solve problems Handle Change management IssuesHandle Change management Issues

The project completion requirements will give savings & benefits The project completion requirements will give savings & benefits to clients right from wave 1. There have been instances where to clients right from wave 1. There have been instances where the client had offset or exceeded cost of training even before the the client had offset or exceeded cost of training even before the end of the programend of the program


Benefits

Typical savings through Lean Master projects in the past include:Typical savings through Lean Master projects in the past include: Up-to 50% reduction in bottleneck machine setup timeUp-to 50% reduction in bottleneck machine setup time OEE improvement in capital intensive machines by up-to 30%OEE improvement in capital intensive machines by up-to 30% Reduced excess WIP holding up to 50% resulting in savings up to RM Reduced excess WIP holding up to 50% resulting in savings up to RM

20,000,000 (one-off saving)20,000,000 (one-off saving) Reduced Cycle Time by up to 30%Reduced Cycle Time by up to 30% Reduced Scrap up to 2% (amounting to about USD120,000/year)Reduced Scrap up to 2% (amounting to about USD120,000/year) Capital avoidance by up to USD1,200,000 Capital avoidance by up to USD1,200,000


Credentials

“ Lean Manufacturing in general opinion is too BIG and difficult to be achieved. But with AMC as our trainer/consultants Lean has become easily understood by Belton candidates of all levels. Lean has become applicable in Belton”

Pongyut, Director of Engineering Belton Industrial, Thailand

“….result is...very ordinary people here ( Production Supervisors, Engineers), moving on very ordinary projects ( Poka--yoke, UPH improvement, Kanban system, etc) for some VERY extra-ordinary results. I am very pleased that so much dollars and cents has been saved with a lot of simple, sensible and stellar projects.

Keep up the good work and I am so proud with all of you.”

Comment of Managing Director of Finisar to AMC Lean Master Candidates


Credentials

“ Lean Manufacturing came at the right time to save millions of dollars for us in capital avoidance…”

Michael, Lean/Engineering Manager MSP, Ipoh (NSK Group)

“ Lean Manufacturing is an effective tool to reduce wastage, optimize capacities & reduce costs….AMC’s course taught us the effectiveness of various Lean Tools….The course is very interactive and the simulation games are very interesting. The course instructors use their extensive industrial experience to elaborate important points and make participants understand the key points”

Roger Goh, Vice President Beyonics Precision, Johore Bahru


LEAN MASTERS ARE CHANGE AGENTSWHO INCREASE PROFITABILITY

advanced manufacturing consultancy sdn. bhd. lean master program

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