Lean Manufacturing
Training Malaysia
Build a factory that flows — not one that just runs faster.
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.
Get a Training Proposal →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.
What Participants Walk Away With
- ✓Map the current state of a production value stream accurately
- ✓Identify and quantify all seven forms of waste
- ✓Design a future state VSM with flow and pull principles
- ✓Build a prioritised Lean implementation roadmap for your factory
Programme Modules
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
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
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
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
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
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, delivered projects across 11 countries and 21 international factories, 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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Tell us your team size, dates, and which programme you need. We'll send a tailored proposal with full HRDC documentation support within 48 hours.