HRD Corp Training Programme No: 10001737359

Course Overview

Manufacturing organisations today face increasing pressure to improve productivity, reduce costs, eliminate waste and remain competitive. Kaizen, a Japanese philosophy of continuous improvement, provides a practical and proven framework for achieving operational excellence through small but consistent improvements.

This comprehensive two-day programme equips participants with practical Lean Manufacturing and Kaizen tools that can be implemented immediately in the workplace. Participants will learn how to identify waste, solve operational problems, improve production processes and build a culture where every employee contributes to continuous improvement.

The programme combines instructor-led learning, case studies, group discussions, simulations and practical workshops to ensure participants gain hands-on experience that can be applied directly within their organisation.

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Who Should Attend

This programme is suitable for:

• Production Managers
• Manufacturing Managers
• Operations Managers
• Production Supervisors
• Engineers
• Process Engineers
• Industrial Engineers
• Quality Engineers
• Maintenance Engineers
• Continuous Improvement Teams
• Lean Coordinators
• Kaizen Facilitators
• Plant Managers
• Warehouse Supervisors
• Supply Chain Personnel
• Team Leaders
• Production Executives
• Manufacturing Executives
• Quality Assurance Personnel
• Anyone involved in improving manufacturing performance

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Learning Outcomes

Upon completion of this programme, participants will be able to:

• Understand the Kaizen philosophy and continuous improvement culture.
• Recognise and eliminate the 8 wastes (Muda) within manufacturing operations.
• Apply PDCA, 5S, Visual Management and Standard Work techniques.
• Conduct Root Cause Analysis using 5 Why and Fishbone Analysis.
• Improve productivity, quality, safety and operational efficiency.
• Reduce process variation and production waste.
• Develop sustainable Kaizen initiatives within their departments.
• Create a practical workplace Kaizen implementation plan.

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Key Topics Covered

Module 1

Introduction to Kaizen

• Kaizen Philosophy
• History of Kaizen
• Continuous Improvement Culture
• Employee Involvement

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Module 2

Lean Thinking & Waste Elimination

• Value Added vs Non-Value Added
• 8 Wastes (Muda)
• Mura
• Muri
• Lean Thinking

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Module 3

Kaizen Improvement Tools

• PDCA Cycle
• 5S
• Standard Work
• Visual Management
• Poka-Yoke
• Gemba Walk
• Process Mapping

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Module 4

Root Cause Analysis

• Problem Identification
• 5 Why Analysis
• Fishbone Diagram
• Pareto Analysis
• Corrective & Preventive Actions

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Module 5

Kaizen Event & Team Problem Solving

• Kaizen Blitz
• Brainstorming
• Team Roles
• Action Planning
• Improvement Presentations

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Module 6

Productivity Improvement

• Cycle Time Reduction
• Motion Study
• Line Balancing
• Work Simplification
• SMED Overview
• Productivity Measurement

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Module 7

Sustaining Kaizen Culture

• Daily Kaizen
• Suggestion Systems
• KPI Monitoring
• Leadership
• Continuous Improvement Roadmap

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Module 8

Kaizen Implementation Workshop

• Manufacturing Case Study
• Waste Identification
• Root Cause Analysis Workshop
• Improvement Planning
• Team Presentation
• Workplace Action Plan

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Practical Activities

Participants will experience interactive learning through:

• Kaizen Quiz
• Find the Waste Ice Breaking
• Gemba Walk Simulation
• Process Mapping Workshop
• Waste Identification Exercise
• 5 Why Workshop
• Fishbone Analysis Workshop
• Kaizen Blitz Team Project
• Manufacturing Case Studies
• Team Presentations
• Personal 30-Day Kaizen Action Plan

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Training Methodology

The programme incorporates a practical and engaging learning approach:

• Interactive Lectures
• Group Discussions
• Manufacturing Case Studies
• Practical Workshops
• Kaizen Simulations
• Team Exercises
• Root Cause Analysis Activities
• Process Mapping Exercises
• Action Planning
• Workplace Application

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Benefits to Organisations

After attending this programme, organisations can expect:

• Reduced operational waste
• Increased manufacturing productivity
• Better quality performance
• Improved process consistency
• Lower operating costs
• Stronger employee engagement
• Continuous improvement culture
• Better teamwork
• Improved customer satisfaction
• Higher profitability

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Industries Suitable

This programme is ideal for:

• Automotive
• Electronics
• Aerospace
• Food Manufacturing
• Oil & Gas
• Heavy Engineering
• Medical Devices
• Plastic Manufacturing
• Packaging
• Semiconductor
• FMCG Manufacturing
• General Manufacturing

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What’s Included

• Professional Training Materials
• Practical Exercises
• Group Activities
• Case Studies
• Certificate of Completion
• Refreshments (Public Programme)
• Lunch (Public Programme)