HRDC Claimable
Training Courses
How to Claim
All programs claimable under SBL-Khas. We handle all documentation.
Register with HRD Corp
Ensure your company is registered at hrdcorp.gov.my — most employers with 10+ staff qualify
Submit Training Grant
Apply for SBL-Khas before training begins — we provide all supporting invoices and documents
Attend & Claim
Complete training, submit attendance records — HRD Corp reimburses fees directly to your company
Training Courses
Nine core HRDC claimable programs, supported by specialist modules for quality, maintenance, productivity, leadership, and digital operations. Each program is built around your industry, your team, and your operational challenges.
Overall Equipment Effectiveness (OEE)
Malaysia's most critical manufacturing metric — and most commonly measured incorrectly. This program goes beyond the formula: participants learn to design an OEE measurement system from scratch, identify Six Big Losses with factory-floor precision, and run improvement sprints that produce measurable results.
- Design and implement an OEE measurement system
- Identify and categorize Availability, Performance & Quality losses
- Run targeted 90-day improvement sprints on the shop floor
Kaizen Principles & Applications
Participants learn to plan and facilitate Gemba-based improvement events, apply PDCA rigorously to real problems, and build the internal structure for continuous improvement that actually sustains beyond the training day.
- Plan and facilitate rapid Kaizen improvement events
- Apply PDCA cycles to real, live operational problems
- Embed continuous improvement into daily team routines
Lean Manufacturing
A practical Lean Manufacturing programme for teams that need to understand waste, flow, visual control, and the improvement tools that stabilise daily operations. Participants learn how Lean fits with Kaizen culture and how to apply the core tools in a factory context.
- Identify the 7 hidden wastes in manufacturing operations
- Apply 5S, visual controls, TPM, Poka-Yoke, JIT, SMED, and Jidoka basics
- Use a practical factory activity to connect Lean concepts to real work
Value Stream Mapping
A hands-on VSM programme for teams that need to see the full process flow, expose bottlenecks, and separate value-added from non-value-added work. Participants learn to build current-state and future-state maps, then convert the map into an implementation plan.
- Create current-state and future-state value stream maps
- Identify bottlenecks, waste, non-value-added activity, and improvement targets
- Develop an implementation plan to sustain process-flow improvements
5S Workplace Organization
Thousands of Malaysian factories run 5S training. Most see initial results that fade within six months. This program focuses specifically on what makes 5S stick — audit design, visual management systems, accountability structures, and the leadership behaviours that sustain the standard.
- Execute a complete Sort, Set-in-Order, Shine, Standardize, Sustain cycle
- Design visual management boards and 5S audit systems
- Build self-sustaining 5S habits and team accountability
Total Productive Maintenance (TPM)
Unplanned breakdowns are one of the biggest OEE killers in Malaysian manufacturing. This TPM program builds the systems to prevent them — transitioning maintenance culture from reactive firefighting to proactive ownership. Participants implement the two foundational TPM pillars (autonomous and planned maintenance) with practical tools they can deploy immediately on the production floor.
- Launch an autonomous maintenance programme with operators
- Design planned maintenance schedules and systems
- Reduce unplanned downtime and equipment failure rates
Total Quality Management (TQM)
Quality cannot be inspected into a product — it has to be built in at every stage of the production process. This TQM program covers quality culture transformation, defect prevention through process control, cross-functional quality ownership, and the management systems that make quality a shared organizational value rather than a QA department responsibility.
- Establish a total quality culture across all production functions
- Implement process control and defect prevention systems
- Drive quality improvements through structured management frameworks
Problem Solving Methodologies
Most factory teams jump to solutions before they have properly defined the problem — and the same issues recur month after month. This program builds systematic root-cause analysis capability using 8D, 5-Why, Fishbone Diagrams, Pareto Analysis, and A3 thinking. Participants work on real problems from their own production environment throughout the training, not textbook examples.
- Apply 8D and A3 frameworks to live production problems
- Conduct root-cause analysis using 5-Why and Fishbone methods
- Prevent problem recurrence with structured countermeasures
AI & Industry 4.0 Training Malaysia
Malaysian manufacturers face real competitive pressure from automation and AI adoption — but most AI training is filled with jargon and theory disconnected from the factory floor. This program is different: practical, clear, and focused on what AI actually means for production operations. Participants assess their own Industry 4.0 readiness and leave with a realistic digital transformation roadmap, not a buzzword deck.
- Understand real AI and IoT use cases on the factory floor
- Assess your organization's Industry 4.0 readiness honestly
- Build a pragmatic, phased digital transformation roadmap
Additional Training Programs
Additional HRDC claimable programmes available for in-house delivery. These can be delivered as standalone sessions or combined into a customised training plan based on your team's needs.
Gemba Management
2 DaysBuild leader capability to observe the real workplace, ask better questions, and turn floor observations into improvement actions.
- Gemba Walk principles: real place, real thing, real facts
- Waste observation using Muda, Mura, and Muri
- Respectful inquiry, team engagement, and follow-up discipline
Development of SOP & Work Instruction
2 DaysHelp teams write clear, visual, operator-friendly procedures that support safety, quality, training, and consistency.
- Difference between SOP, WI, checklist, and One Point Lesson
- Task sequencing, visual aids, validation, and document control
- Hands-on drafting and testing of a real work instruction
7 Quality Control Tools (7 QC Tools)
2 DaysTrain teams to use the classic quality tools for defect analysis, process monitoring, and structured improvement.
- Check sheets, Pareto, histogram, scatter, control chart, and fishbone
- Data collection methods for production and quality issues
- Using data to verify root causes and communicate findings
Failure Mode & Effects Analysis (FMEA)
2 DaysEquip engineering, production, and quality teams to identify process and product risks before failures reach the customer.
- DFMEA, PFMEA, AIAG-VDA option, failure modes, effects, causes, controls, and RPN
- Severity, occurrence, detection, and action prioritization
- Manufacturing case studies and mitigation planning
8D Report & CAPA Problem Solving
2 DaysBuild a disciplined 8D reporting approach for customer complaints, internal defects, and recurring production problems.
- Containment, team formation, root cause, corrective action, and prevention
- Linkage with RCA, FMEA, verification, and evidence gathering
- Standardized 8D reporting and management review routines
SMED Changeover Reduction
2 DaysReduce setup time and improve production flexibility using Single Minute Exchange of Die methodology.
- Separate internal and external setup activities
- Video or live observation of changeover waste and bottlenecks
- Standardized setup procedure, visual controls, and action plan
Yamazumi Chart & Line Balancing
2 DaysUse visual workload analysis to improve line balance, reduce waiting, and align production work to takt time.
- Task breakdown, time study, cycle time, and takt time
- Create manual or spreadsheet-based Yamazumi charts
- Rebalance work content and standardize the improved line
Rejects & Defects Reduction
2 DaysHelp production and quality teams reduce scrap, rework, warranty claims, and recurring process defects.
- Cost of poor quality, yield, DPPM, and rejection-rate tracking
- Pareto, 5 Whys, fishbone, Poka-Yoke, and process controls
- Team-based defect reduction plan with ownership and KPIs
Business Process Mapping / SIPOC-ICOR
1-2 DaysMake cross-functional handovers visible so teams can fix delays, unclear ownership, and repeated communication breakdowns.
- SIPOC and ICOR mapping for service, logistics, and office processes
- Identify process gaps, handoff risks, and non-value-added work
- Build a clearer future-state process with responsible owners
Organizational Culture of Operational Excellence
2 DaysAlign leadership behaviour, daily routines, and team systems so improvement becomes part of how the organisation works.
- Culture diagnosis, culture map, and desired behaviour definition
- Leadership alignment, resistance, rewards, and feedback loops
- Operational excellence culture roadmap with quick wins and long-term shifts
Effective Supervisory Skills
2 DaysDevelop frontline supervisors who can communicate clearly, coach teams, solve problems, and sustain daily performance.
- Supervisor roles, communication, feedback, and motivation
- Conflict handling, emotional intelligence, delegation, and time management
- Data-driven decision-making and continuous improvement leadership
Manufacturing Foundation
1-2 DaysA practical foundation for new engineers, supervisors, executives, and support teams entering manufacturing operations.
- Manufacturing flow, quality, productivity, safety, and cost fundamentals
- Lean, Kaizen, waste, variation, and problem-solving basics
- Simple workplace exercises to connect concepts to the participant's own process
A3 Problem Solving
2 DaysA structured Toyota-style problem-solving programme that helps teams define problems clearly, analyse causes, and communicate countermeasures on one page.
- A3 thinking, PDCA, current condition, target condition, and gap analysis
- 5 Whys, fishbone, data checks, and countermeasure selection
- Complete an A3 report using a workplace or case-study problem
Root Cause Analysis (RCA)
2 DaysBuild the discipline to separate symptoms from root causes and prevent the same problem from returning.
- Problem statement, symptom vs root cause, and RCA method selection
- 5 Whys, fishbone, Pareto, data gathering, and validation
- Corrective action planning, RCA reporting, and sustainment follow-up
Root Cause Analysis & Problem Solving
1 DayA focused practical programme for teams who need a simple, repeatable way to investigate daily operational issues and prevent recurrence.
- Problem clarification and cause-chain thinking
- Correct use of 5 Whys without jumping to assumptions
- Basic countermeasure and recurrence-prevention worksheet
Lead Time Reduction
1-2 DaysReduce waiting, handoff delays, batching, and process bottlenecks across production or business workflows.
- Current-state process flow, waiting points, and bottleneck analysis
- Waste removal, batch-size review, flow improvement, and pull thinking
- Lead-time improvement action plan with owners and measures
7 Management & Planning Tools (7 MP)
1-2 DaysUse planning and management tools to organise complex issues, align teams, and turn ideas into structured action plans.
- Affinity, relations, tree, matrix, prioritisation, PDPC, and activity network tools
- Group facilitation for complex planning and improvement problems
- Convert analysis into practical project or department action plans
Quality Improvement
1-2 DaysA practical quality improvement programme for teams dealing with repeated defects, customer complaints, or weak process control.
- Quality gap analysis, defect prioritisation, and process observation
- PDCA, 7 QC Tools, root cause analysis, and standardisation
- Improvement plan for quality, rework, scrap, and customer-impact issues
Quality Control
1-2 DaysBuild basic quality control capability for production, QA/QC, and operational teams who need stronger inspection and prevention discipline.
- Quality fundamentals, inspection strategy, defect classification, and acceptance criteria
- Sampling, data capture, visual standards, and reaction rules
- Linking quality control to RCA, FMEA, Poka-Yoke, and standard work
Critical Thinking
1 DayStrengthen how teams question assumptions, interpret information, and make better operational decisions.
- Fact vs opinion, bias awareness, and clearer problem framing
- Cause-effect thinking, evidence checks, and decision criteria
- Practical exercises using workplace scenarios and operational trade-offs
Data Analysis in Problem Solving
2 DaysHelp teams collect, interpret, and use data properly during RCA, PDCA, DMAIC, and improvement work.
- Qualitative vs quantitative data, check sheets, run charts, and Pareto
- Variation, trend, histogram, scatter, stratification, and control charts
- Use data to verify root causes, report findings, and monitor KPIs
Lean Production System
1-2 DaysA focused Lean production programme covering how to design a more stable, visual, waste-conscious production system.
- Lean principles, waste elimination, flow, pull, 5S, visual control, and standard work
- Kanban, basic takt thinking, production stability, and daily management
- Practical improvement roadmap for the participant's production area
Automotive Ecosystem
1 DayIntroduce participants to automotive manufacturing expectations, operational discipline, quality flow, and supplier ecosystem requirements.
- Automotive value chain, supplier expectations, QCD, and delivery discipline
- Lean production, quality control, 5S, and continuous improvement fundamentals
- Practical discussion on readiness for automotive manufacturing operations
Introduction to IR4.0
1 DayExplain Industry 4.0 in plain operational language so teams can understand readiness, use cases, and practical digitalisation steps.
- IR4.0 concepts, smart factory basics, IoT, data, dashboards, and automation
- Readiness assessment across people, process, technology, and data
- Simple digital transformation roadmap for manufacturing teams
Husni Halim
16+ years on the factory floor across semiconductors, aerospace, automotive, oil & gas, and FMCG. Not a classroom-only trainer — a practitioner who ran Kaizen events at Prysmian global plants, delivered projects across 11 countries and 21 international factories, and delivered OEE programmes across 30 Malaysian factories under TERAJU Pritech4.0 as Lead Consultant. Principal Consultant at Visi Armada Consulting.
HRDC Accredited Trainer
Accredited by Human Resource Development Corporation (HRD Corp) Malaysia
MPC QE5.0 Certified Auditor
Malaysia Productivity Corporation — Quality Excellence 5.0 Framework
Certified Process Kaizen Engineer
Solving Efeso Consulting — Milan, Italy
B.Sc. Aerospace Engineering
University of Arizona, USA — 2003
Before You Book
Ready to Book?
Tell me your training needs and I'll put together a customized proposal — including HRDC grant guidance and a program outline built around your team and industry.