Lean Manufacturing
Training Malaysia

Build a factory that flows — not one that just runs faster.

2 Days · In-House Engineers · Supervisors · Managers ✓ HRDC Claimable (SBL-Khas)

100% HRDC Claimable — All programmes delivered by an HRDC Accredited Trainer. Fully claimable under the SBL-Khas scheme. We assist with documentation and grant application.

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What This Programme Covers

Lean is not a cost-cutting programme — it is a system for making value flow without interruption. Malaysian factories that implement Lean tools without understanding the system behind them get islands of improvement that don't connect. This program builds genuine Lean capability: participants understand the principles first, then learn the tools that serve those principles. Value Stream Mapping is used throughout as the primary diagnostic framework — giving teams a shared language for seeing waste and planning the future state.

Duration
2 Days (16 Hours)
Group Size
10–25 participants
Who Should Attend
Industrial engineers, production engineers, supervisors, managers, planning team...
Delivery
In-house at your facility across Malaysia

What Participants Walk Away With

Programme Modules

M1

Module 1: Lean Principles

  • Value from the customer's perspective
  • The value stream — all steps from raw material to customer
  • Flow, pull, and the pursuit of perfection
  • Lean vs efficiency — why they are not the same thing
M2

Module 2: Waste Identification

  • 7 Wastes (Muda) with factory-floor examples
  • Mura (unevenness) and Muri (overburden)
  • Value-added vs non-value-added vs necessary non-value-added
  • Waste walk: live observation exercise
M3

Module 3: Value Stream Mapping (VSM)

  • Current state map: how to draw and read one
  • VSM data box metrics: CT, C/O, uptime, shifts
  • Identifying the bottleneck and constraint points
  • Future state design principles
M4

Module 4: Flow and Pull Systems

  • One-piece flow vs batch-and-queue
  • Takt time calculation and production levelling
  • Kanban system design principles
  • FIFO lanes and supermarket design
M5

Module 5: Lean Tools in Practice

  • 5S as the foundation of visual flow
  • Standard work: takt, sequence, WIP
  • Quick changeover (SMED) basics
  • Error-proofing (Poka-Yoke) overview
M6

Module 6: Future State Planning

  • Teams build a future state VSM for their own production area
  • Kaizen burst identification and prioritisation
  • Implementation roadmap with 30/60/90-day milestones

Previously Delivered At

  • Prysmian Group (Global VSM programme)
  • TERAJU Pritech 4.0 (Lean deployment, 30 factories)
  • Plexus Manufacturing (2024)
  • KFC Supply Chain Malaysia (2023)

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 across five countries and delivered OEE programmes across 30 Malaysian factories under TERAJU Pritech 4.0 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

Certified Process Kaizen Engineer

Efeso Consulting — Milan, Italy

B.Sc. Aerospace Engineering

University of Arizona, USA — 2003

Before You Book

No. The program starts from fundamentals and builds systematically. Participants with existing Lean exposure typically find they fill significant gaps in understanding.

Yes. Day 2 includes a VSM exercise on a production area selected by the client. Participants map a real current state and design a real future state — not a textbook example.

Factory-floor context throughout. No case studies from automotive companies if your factory makes electronics. All examples, exercises, and the VSM session are calibrated to your industry.

Yes. The standard 2-day programme can be extended with a full-day VSM practicum where participants complete a detailed future state and implementation plan. Ask about the extended format.

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