Lean Approach to Optimize Productivity and Efficiency (In-House Training)Business Management / Sustainability

Introduction

The concept of Lean Management is a quantum leap in the advancement of organisational efficiency. The results include process improvement, better resource utilisation, corporate vision and objectives, better cost management, and enhanced productivity and competitiveness.
The pace and complexity of competition due to such common themes as globalisation, Information Technology and Internet revolution are so relentless. They will become even more that the organisation finds it tough to maintain its edge without sustained and continuous improvement.

Key Takeaways

Upon completion of this workshop, participants will be able to;

• Understand the concepts and implementation of Lean Organisation and using Lean to improve processes
• Have sound knowledge of Poka-Yoke (mistake proofing)
• Enhance awareness of wastes reduction
• Play constructive roles in supporting improvement
• Link productivity to wastes in the organisation
• Improve current processes to a more optimum level
• Achieve a practical connection between Vision and Reality

Who Should Attend

Managers, officers, executives, and operatives personnel from all industries and those who wish to improve their understanding and skills concerning the application of lean management leading to process and productivity improvement.

Programme Outline

Module 1: Introduction to Lean

• What is Lean Concept?
• 3 key Pillars of Lean
• Benefits of Being Lean

Module 2: Organisational “Wastes” and How they hinder productivity

• Relationship between waste and productivity
• Enhancing productivity with the Lean concept
• Requirements for implementation
• Case Study

Module 3: Performance and Skills: Closing these gaps

• Looking at performance differently: case commentary on “efficiency.”
• Avoiding “busy bees, no honey” syndrome
• Skills matrix: what are the gaps?
• Case: From Vision to practicality

Module 4: Your Value Stream: Processes revisit

• Definition of value-add activities, tasks, and jobs
• Examples of processes that are wasteful
• Workshop on the depth of each wasteful activity
• Your processes revisit: critique and commentary
• Workshop: What new/revised processes are necessary?

Module 5: Poke-Yoke or Mistake Proofing

• Introduction and picture/video comments
• Examples of devices
• The 4 levels of effectiveness
• Case discussion

Module 6: The Roles of Management and Staff

• Types of Leadership Styles supporting improvement
• Techniques for Managing Change: there CANNOT be improvement without change
• Applying these changes to the organisation

Summary

• Identify wastes in your area
• Key Tools
• Compile results and/or key learning

Methodologies

The course will be delivered through a combination of Metaphoric and Learning-By-Doing approaches. The participants will be going through various simulation scenarios that interact with the subject itself. At each stage, the participants will need to exercise the techniques taught and practice them to self-develop their skills.

The active learning activities may include:

• Hands-on exercises
• Group discussions
• Case studies
• Interactive storytelling
• Commentary on other companies/industries
• Video presentation

Programme Trainer

Mr Andrew Cheah, an MBA degree qualification from the University of Portsmouth, UK, has been a trainer and management consultant since 1991, specialising in performance management, productivity improvement, behavioural change, and leadership. Andrew has trained clients from such diverse industries (see list below) as banking, insurance, hospitality, sales and distribution, manufacturing, food, property development, government/public services, and higher education. Being tri-lingual (English, Mandarin, and Malay Languages), Andrew has extensive regional exposure in Singapore, United Arab Emirates, Malaysia, China, Thailand, Indonesia and Vietnam.

In addition to training, Andrew has guided and provided consulting services to clients, leading to one of them winning the prestigious Malaysian National Productivity Award presented by the previous Malaysian Prime Minister, Tun Dr Mahathir. Andrew has also been invited to speak in events such as the International Conference on Best Practices, which was graced by senior officials from the Ministry of International Trade and Industry (MITI), sharing the stage with Professor Michael Gregory of the University of Cambridge, Mr Dieter Heyl, Vice President of Mercedes Benz Malaysia (2007), and Dr Marcus Chao, President of Lean China Enterprise Inc.

Andrew has a certificate in Blue Ocean Leadership Masterclass and Leading Dimensions Profiling Trainer Certification (LDP certified) at the professional level. In addition to being a qualified ISO9000 assessor, his experience in international consultancy has also earned him a membership with the Association of Productivity Specialist (New York).