Problem Solving Training Malaysia

01Programme Overview

What This Programme Covers

The same problems recur in most Malaysian factories because root cause analysis is done in name only — teams jump to containment, close the corrective action ticket, and watch the same failure mode reappear six weeks later. This program builds systematic problem-solving capability using the methods that actually prevent recurrence: 8D, 5-Why, Fishbone (Ishikawa), Pareto Analysis, and A3 thinking. Every tool is applied to real production problems from the participants' own factory — not textbook examples.

Duration

1–2 Days (8–16 Hours)

Group Size

10–20 participants

Who Should Attend

Production engineers, QA engineers, maintenance engineers, supervisors, section ...

Delivery

In-house at your facility across Malaysia

What Participants Walk Away With

✓Apply 8D methodology to real production problems with proper root cause verification
✓Use 5-Why and Fishbone correctly — avoiding the most common facilitation mistakes
✓Write an A3 that communicates problem, analysis, and countermeasure clearly
✓Build a corrective action system that prevents the same problem from recurring

02Programme Content

Programme Modules

M1

Module 1: Problem-Solving Mindset

Why problems recur — the containment trap
Defining the problem correctly (is / is not analysis)
Problem vs symptom vs root cause
The cost of poor root cause analysis

M2

Module 2: Data-Driven Problem Definition

Pareto Analysis — finding the vital few
Run charts and trend analysis
Stratification to isolate the problem
Operational definitions for accurate data collection

M3

Module 3: Root Cause Analysis Tools

5-Why — rules for effective use and common mistakes
Fishbone (Ishikawa) Diagram: 4M and 6M frameworks
Fault tree analysis introduction
Cause-and-effect matrix for prioritisation

M4

Module 4: 8D Problem Solving Process

D1–D8 overview: team, problem statement, containment, root cause, corrective action, validation, prevention, closure
Permanent corrective action vs containment action
Verification methods: controlled trials, DOE basics
PFMEA linkage for prevention

M5

Module 5: A3 Thinking

A3 report structure and purpose
Writing an A3 that communicates clearly
A3 as a coaching and problem-solving discipline
A3 review and PDCA integration

M6

Module 6: Live Problem-Solving Workshop

Teams select a real recurring production problem
Full 8D analysis completed during the session
Root cause verified with data
Permanent corrective action proposed and reviewed

Previously Delivered At

Panasonic Aircond (2025)
Plexus Manufacturing (2024)
Automotive Tier-1 supplier (2023)
Aerospace MRO (2023)

03Your Trainer

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

04Common Questions

Before You Book

What is the difference between the 1-day and 2-day formats?

The 1-day format covers the essential tools (5-Why, Fishbone, 8D) with a focused workshop. The 2-day format adds A3 thinking, a deeper Pareto/stratification module, and a full live problem-solving session where teams complete a real 8D on a production problem. Most clients find the 2-day format produces significantly better skill retention.

Do we need to prepare problems in advance?

Yes — participants are asked to bring 2–3 recurring production problems to the training. These become the raw material for all workshop exercises. This is what separates this program from classroom-only training.

Is this training suitable for operators?

The 1-day format (5-Why and Fishbone focus) is well-suited for operator and team leader groups. The 2-day format with 8D and A3 is typically for engineers and supervisors. Both are HRDC claimable.

Can problem solving training be combined with other programmes?

Yes — commonly combined with TQM (2+1 days), Lean (2+1 days), or OEE (as a standalone complement). All combinations are claimable under a single HRDC grant application.

05Related Programmes

Other Training Courses

Further Reading PDCA in Malaysian SMEs: Why It Always Gets Stuck at Plan →

Problem SolvingTraining Malaysia