Husni Halim
Principal Consultant, Certified Process Kaizen Engineer · GSDC Certified in Global Leadership Excellence
Transforming Malaysian manufacturing operations through Lean methodologies, Kaizen engineering, and data-driven Operational Excellence — delivering measurable results for over 16 years, across Malaysia, 11 countries, and 21 international factories.
⚡ Quick Answer: Husni Halim is an EFESO-certified Process Kaizen Engineer, GSDC Certified in Global Leadership Excellence, and HRDC-accredited trainer (ID: 11294) specialising in OEE improvement, Kaizen implementation, and Lean manufacturing for Malaysian SMEs and MNCs. Based in Shah Alam, serving clients nationwide including Penang, Johor, and Perak. Explore Kaizen expertise →
Trusted Across Industry
A selection of 84 organisations and project sites from training, consulting, HRD Corp public programs, TERAJU Pritech4.0, and international improvement work across 11 countries and 21 international factories.
Services & Offerings
From a single training session to a full-year coaching engagement — tailored to where your organisation is today.
Free Site Assessment
A structured review of your current manufacturing operations, lean readiness, and improvement opportunities. Identify quick wins and strategic focus areas with zero commitment.
Schedule Free AssessmentProduction Line Improvement
Focused support for missed output, bottlenecks, downtime, rework, unstable cycle time, and daily firefighting on Malaysian production lines.
Improve the LineConsulting Engagements
Tailored consulting to implement lean systems, optimise processes, and embed continuous improvement culture. Short-term projects or ongoing partnership — your choice. HRDC claimable.
Discuss ConsultingHRDC Training Programs
Group training sessions covering Kaizen, 5S, OEE, VSM, standard work, and more. 100% HRDC claimable. Public batches and customised in-house programs available.
View TrainingTrusted by Industry Leaders
Husni brings a rare combination of deep subject matter knowledge and practical professionalism. He guided participants through a genuinely difficult task — identifying broken processes, weak links and misallocated resources within their own organisations. Deadlines were met, commitments were kept and there was never a need to follow up twice. I recommend him without reservation to any organisation looking for someone who delivers, not just promises.
Husni was a fantastic collaborator during our time in the MARii IPC program. He brings a unique blend of strategic thinking and hands-on technical knowledge to the table. What impressed me most was his focus on sustainable results and his willingness to share insights that elevated the entire team's performance. He is a true professional and a valuable asset to the Malaysian industrial consulting landscape.
Husni Halim has been a valued partner consultant with us since 2022, contributing significantly to operational performance improvement initiatives. He brings strong analytical discipline, practical problem-solving, and a structured approach to driving efficiency and measurable results. Husni consistently demonstrates reliability, professionalism, and the ability to translate strategy into execution. A dependable collaborator trusted to deliver with impact.
Huge thanks to Husni for leading our Carotino 5S project! His consulting was clear, practical, and highly effective. Our team is more organised and productive thanks to his guidance in 5S practices. If you need a consultant who knows how to make 5S stick and drive efficiency, Husni is the expert you want.
Factory Floor Experience, Not Textbook Theory
Mohd Husni Bin Abd Halim is a HRDC-accredited trainer, EFESO-certified Process Kaizen Engineer, and GSDC Certified in Global Leadership Excellence. His Kaizen credential was obtained from EFESO Consulting in Milan, Italy, one of the world's premier manufacturing consultancies. He is also a Malaysia Productivity Corporation (MPC) QE5.0 External Auditor.
With a BSc in Aerospace Engineering from the University of Arizona (2003) and over 16 years in heavy manufacturing — including a decade-long tenure at Prysmian, the world's largest power cables company — Husni has led improvement projects across Malaysia, Italy, Brazil, China, Indonesia, and Norway.
He currently serves as Lead Consultant for TERAJU's Pritech 4.0 initiative, overseeing OEE system implementation across 30 Bumiputera factories, and as Lead Trainer for MARii's Automotive IPC Program, having trained 330+ participants at UPM and PESDC.
His approach is grounded in factory-floor reality — not theory. Every program he delivers is built around the actual challenges Malaysian manufacturers face: resource constraints, cultural transitions, and building improvements that stick long after the engagement ends.
Managing Director, Visi Armada Consulting — HRDC Registered Training ProviderLean & Kaizen Expertise
Every tool and methodology below has been applied on real factory floors — not just taught from slides.
Kaizen Events & Culture
Move beyond one-off events to build sustainable continuous improvement culture. Design and facilitate Kaizen events that produce real results and genuine team buy-in. View the Kaizen hub.
Overall Equipment Effectiveness (OEE)
Measure and improve OEE with data-driven dashboards and analytics. Practical OEE implementation for IR 4.0 applications — proven across 30+ factories through TERAJU Pritech 4.0. Use the OEE calculator.
5S & Visual Management
Implement 5S programs that stick beyond training day. Design visual management boards that actually drive daily behaviour — not decoration.
Value Stream Mapping (VSM)
Identify and eliminate waste. Map current and future states to guide strategic improvement priorities across your production flow.
Root Cause Analysis & Problem Solving
A3, 5 Whys, Fishbone, 8D, 7 QC Tools — the full problem-solving toolkit applied to real manufacturing challenges, not classroom simulations.
Standard Work & Process Discipline
Create and enforce standard work that becomes the baseline for continuous improvement. SOP and work instruction development that operators actually follow.
Total Productive Maintenance (TPM)
Reduce breakdowns, increase uptime, and build a maintenance culture that operators own. Practical TPM implementation aligned with production realities. View TPM training.
Production Leadership Coaching
Coaching for plant managers, supervisors, and team leads to lead lean transformation. Build internal champions, not dependency on external consultants. Explore production line improvement.
Selected Improvement Work
Examples of operational improvements delivered through structured problem solving, team involvement, and practical follow-through.
Carotino Sdn Bhd
TERAJU Pritech 4.0
MARii Automotive IPC Program
Malaysia Airlines Berhad Engineering Service (MABES)
Sound familiar?
If any of these describe your operation, you're not alone — and you're in the right place.
Training happens. Then nothing changes.
Your team sits through the workshop, nods along, then returns to the same habits on Monday morning.
Improvements last three months — then quietly disappear.
The 5S audit looked great. Six months later the workspace looks exactly like before the engagement.
No one owns continuous improvement.
Everyone agrees it matters. Nobody's job it actually is to make it happen every single week.
Develop internal leaders for sustained improvement.
Most operations know what needs to improve. The missing piece is someone inside the organisation who owns the method, leads the team, and sustains the gains — without depending on external consultants month after month. That's what this program builds.
- Kaizen methodology, event design & facilitation
- 5S, VSM, standard work, OEE tools
- Root cause analysis & A3 problem solving
- Change management & team leadership
- 90-day post-program implementation coaching
Build Lean Capability in Your Team
All programs are HRDC claimable. Available as public batches or customised in-house delivery at your facility.
Kaizen Champion Program
Intensive immersion for manufacturing leaders and coordinators. Master Kaizen event facilitation, lean tools, and change leadership. Build your internal champion.
- Kaizen methodology and event design
- 5S, VSM, standard work development
- A3 & root cause analysis
- Team dynamics and resistance management
- 120-day post-program support
Practical Kaizen Culture Framework
A structured approach to identifying and resolving production bottlenecks and wastages. Teaches a repeatable method to stabilise processes and maintain improvements through team-led discipline.
- Pinpoint inefficiencies in daily production flow
- 7 QC Tools and jidoka, poka-yoke, genba
- PDCA cycle and data-driven decisions
- Practical sustainable culture development
OEE — Overall Equipment Effectiveness
From fundamental OEE principles to practical execution on the shop floor. Learn to build OEE dashboards, run downtime analysis, and drive measurable productivity gains.
- OEE principles & metrics
- Data collection and downtime analysis
- Building OEE dashboards and reporting
- In-depth factory use-case projects
5S & Waste Reduction
Remove obstacles that slow down production. Identify hidden wastes like unnecessary movement, waiting times, and rework — and make daily workflow smoother and more effective.
- Spot waste and add-no-value tasks
- Organise for speed with 5S
- Visual controls for instant problem visibility
- Standardise and sustain improvements
Lean, Problem Solving & Cultural Organisation
Develop a sustainable culture where employees become systematic, data-driven problem solvers — and lean principles become part of daily operations.
- Recognise & reduce 8 types of waste
- Data-driven organisation and improvement
- Root cause analysis using 7 QC tools
- Prioritisation matrix and improvement culture
Custom In-House Programs
All programs can be delivered in-house, customised to your specific processes, challenges, and team. Minimum group discounts available. Bilingual delivery (English & Malay) available.
- Any topic from the training portfolio
- Customised content for your industry
- On-site with real factory-floor exercises
- 100% HRDC claimable
Manufacturing Leadership Blog
Practical guides on lean manufacturing, Kaizen, and operational excellence. Written from factory-floor experience — not theory.
Let's Talk About Your Operations
Whether you're looking to start a Kaizen program, book a training session, or just want to understand what's possible in your facility — reach out. I respond to all enquiries within 1 business day.