HRDC Claimable · May 18–22, 2026 · Shah Alam

Kaizen Champion
Development Program

Embedded continuous improvement for manufacturing excellence

A comprehensive five-day program for engineers, operations managers, and team leaders who drive sustainable operational improvement. Learn proven methodologies from 16+ years of deployment across Malaysia and 6 countries.

Reserve Your Spot View Curriculum
5
Intensive Days
90
Days Coaching
10×
Average ROI
15
Max Cohort Size

Why Kaizen?

Kaizen — continuous improvement embedded in daily operations — is the difference between reactive firefighting and systematic, sustained improvement. Organizations that embed this methodology see measurable results within weeks.

Investment Returns: Typical kaizen projects eliminate RM 50,000–80,000 in annual waste (scrap, downtime, rework, inventory, labour). ROI ranges from 10× within 6 months. Most organizations recover the program investment from their first improvement initiative.

This is not theoretical training. 80% of the curriculum is applied directly to your operations — using your data, solving your challenges.

Root Cause Analysis

5 Why, Fishbone, and 7QC Tools applied to your actual operational data.

A3 Report Methodology

Communicate improvement logic on one professional page — standard across leading manufacturers.

90-Day Implementation Coaching

Structured coaching to ensure improvements lock in and prevent regression.

Online Coaching Sessions

6 bi-weekly sessions over 3 months. Email support and consultations throughout.

Program Objectives

Participants will develop the knowledge, skills, and mindset to lead sustainable operational improvement.

Kaizen Philosophy & Leadership

Understand the history, principles, and role of a Champion in embedding continuous improvement culture.

Waste Identification

Recognize and quantify the 8 Wastes in your operations — overproduction to underutilized talent.

Baseline Assessment

Establish current state using Quality, Cost, and Delivery (QCD) framework.

Root Cause Analysis

Apply 5 Why, Fishbone diagrams, and systematic thinking to find true causes, not symptoms.

Data-Driven Problem Solving

Master 7QC Tools: Check Sheets, Pareto, Histograms, Control Charts. Decisions on data, not opinion.

Countermeasure Design

Create effective solutions using Poka Yoke, Jidoka, Visual Management, and Standard Work.

A3 Reporting

Develop professional one-page improvement reports. Communicate logic, data, and action plans clearly.

Implementation Leadership

Plan and execute kaizen initiatives with clear ownership, KPIs, pilot strategies, and daily accountability.

Culture & Sustainability

Lock in gains, prevent regression, build internal capability, develop future champions through mentorship.

KPI Management

Design dashboards, quantify business impact, communicate improvement ROI to leadership.

Team Development

Coach team members through PDCA cycles, build problem-solving capability, scale continuous improvement.

Change Leadership

Lead teams through transformation. Manage resistance, build buy-in, sustain momentum.

Learning Outcomes

What participants leave with after 5 days

Knowledge

  • Kaizen philosophy and competitive advantage
  • The 8 Wastes (Muda) framework
  • QCD business impact model
  • PDCA continuous improvement cycle
  • Root cause analysis methodologies
  • 7 Quality Control Tools
  • Poka Yoke and Jidoka concepts
  • A3 Report structure and logic

Technical Skills

  • Baseline assessment and data collection
  • Systematic root cause analysis
  • Apply 7QC Tools for data analysis
  • Design countermeasures and controls
  • Facilitate 5S audits and assessments
  • Document standard work procedures
  • Create professional A3 Reports
  • Lead daily management reviews
  • Develop KPI dashboards
  • Coach team members through PDCA

Leadership Mindset

  • Waste exists in every process
  • Reality is on the factory floor
  • Data drives every decision
  • Root causes are systemic, not personal
  • Small improvements compound exponentially
  • Culture sustains results long-term
  • Frontline staff are your best experts
  • Lead by coaching, not controlling

5-Day Curriculum

May 18–22, 2026  |  9:00 AM – 5:00 PM  |  De Palma, Shah Alam

Limited to 15 participants per cohort

Day 1Foundation of Kaizen ▲
MORNING: 9:00 AM – 1:00 PM
  • Program Overview & Participant Introductions — Setting context and building group cohesion
  • Kaizen: Philosophy & Historical Context — Origins, evolution, and relevance to modern operations
  • The Role of a Kaizen Champion — Responsibilities, required competencies, organizational impact
  • QCD Framework — Quality, Cost, Delivery and their interconnection to profitability
  • The PDCA Cycle — Plan-Do-Check-Act as the engine of continuous improvement
AFTERNOON: 2:00 PM – 5:00 PM
  • Reactive vs. Proactive Mindset — From crisis management to prevention
  • Champion Competencies Framework — Technical, leadership, and change management skills
  • Operational Excellence Case Study — Analysis of successful improvement methodologies
  • PDCA Exercise: Applied Problem Solving — Small group practice on operational challenges
  • Personal Goal Setting — Individual commitment to learning and action
Day 2Baseline & Problem Identification ▲
MORNING: 9:00 AM – 1:00 PM
  • The 8 Wastes (Muda) — Overproduction, Waiting, Transport, Processing, Inventory, Motion, Defects, Talent
  • Baseline Metrics & KPIs — Cycle time, defect rate, downtime, lead time, labour productivity
  • Assessment Methodology — Systematic approach to understanding current state
AFTERNOON: 2:00 PM – 5:00 PM
  • Waste Identification Workshop — Recognize each type of waste in your process
  • 5S Framework — Sort, Set, Shine, Standardize, Sustain: organizing for efficiency
  • Data Collection Planning — Define process, select metrics, assign ownership, establish timeline
Day 3Root Cause Analysis & Solutions ▲
MORNING: 9:00 AM – 1:00 PM
  • 5 Why Analysis Method — Drilling down to true root causes
  • Fishbone Diagram Construction — Man, Machine, Method, Material, Environment framework
  • 7 Quality Control Tools — Check Sheet, Pareto, Histogram, Run Chart, Scatter Plot, Stratification, Control Chart
AFTERNOON: 2:00 PM – 5:00 PM
  • Data Analysis Workshop — Apply 7QC Tools to your baseline data, identify patterns
  • Countermeasure Development — Design specific, testable solutions to root causes
  • Implementation Plan Framework — Who, what, when, resources, success metrics
Day 4Implementation & Leadership ▲
MORNING: 9:00 AM – 1:00 PM
  • A3 Report Development — One-page improvement communication: background, analysis, solutions, plan, results
  • Poka Yoke (Mistake-Proofing) — Design processes to prevent errors before they occur
  • Jidoka (Autonomation) — Build in quality; processes stop when abnormality detected
AFTERNOON: 2:00 PM – 5:00 PM
  • Visual Management Systems — Make status, problems, and targets visible at a glance
  • Standard Work Documentation — Best known method: sequence, timing, quality criteria
  • Leading Change — Communicate why, involve staff, train thoroughly, celebrate early wins
  • Pilot & Rollout Strategy — Start small, monitor daily, adjust quickly, scale to full deployment
Day 5Sustainability & Culture ▲
MORNING: 9:00 AM – 1:00 PM
  • Sustainability Strategy — Standard work audits, visual metrics, accountability, recognition
  • Preventing Regression — Monthly reviews, quick-fix protocols, training refreshes
  • Managing Resistance — Address fear, habit, effort, ownership barriers with empathy
AFTERNOON: 2:00 PM – 5:00 PM
  • KPI Tracking & Dashboards — Quality, Cost, Delivery metrics over 90+ days
  • Business Impact Calculation — RM savings, ROI, payback period, link to business strategy
  • Capstone Presentations — Each participant presents A3 Report, peer feedback
  • 90-Day Action Plan Review — Coaching schedule, email support, alumni network, next steps

Program Includes

Everything you need to implement from Day 1 back on the floor

📋

Complete Tools Handbook

A3 templates, Fishbone diagrams, Check Sheets, Pareto charts, 5S assessments, Standard Work forms, Visual Management templates.

📊

Data Analysis Workshop

Apply 7QC Tools to your baseline data. Analyze patterns. Develop countermeasures specific to your operation.

📄

A3 Report Guidance

Template, worked example, peer review during program. Leave with a complete, ready-to-present improvement plan.

🎓

90-Day Coaching

6 bi-weekly online sessions over 3 months, email support, phone consultations. Lock in improvements and prevent regression.

🔍

Process Assessment

Structured evaluation of your current operations using QCD framework. Identify improvement opportunities.

🗺️

Implementation Roadmap

Clear 90-day execution plan with milestones, ownership, KPI targets, and success metrics.

Pricing

HRDC claimable for Malaysian companies

Early Bird

Register by April 30

RM 4,500
  • 5-day intensive program
  • All tools & templates
  • 90-day coaching (6 sessions)
  • Complete A3 Report
  • 90-day Implementation Roadmap
Register Now

Standard

Regular rate

RM 5,000
  • 5-day intensive program
  • All tools & templates
  • 90-day coaching (6 sessions)
  • Complete A3 Report
  • 90-day Implementation Roadmap
Reserve Now

Group Rate

3 or more participants

RM 4,500
  • 5-day intensive program
  • All tools & templates
  • 90-day coaching (6 sessions)
  • Complete A3 Report
  • 90-day Implementation Roadmap
Contact Sales
🏛️

HRDC Claimable

This program is claimable under HRDC (Human Resource Development Corporation). Malaysian companies can offset the full training fee through their HRDC levy. Husni Halim is an HRDC accredited trainer (TTT Trainer ID 11294).

Frequently Asked Questions

Do I need Lean or manufacturing experience?▲
No. This program is self-contained and designed for operations professionals at any experience level. If you've done Lean before, this deepens that knowledge. We assume only that you understand your process.
We tried improvements before. Nothing lasted. Why would this be different?▲
Most improvements fail during the 6 months after training — not because the solution is flawed, but because follow-up is missing. This program includes 90 days of structured coaching to ensure improvements lock in. You get a sustainability plan on Day 5 and support throughout implementation.
Is this customized to our industry?▲
Yes. 80% of the program is applied directly to YOUR process, YOUR challenges, and YOUR data. Whether you're automotive, electronics, food, pharma, or process manufacturing, examples and case studies are adapted accordingly.
What happens after the 5 days?▲
You receive 90 days of structured support: 6 bi-weekly online coaching sessions (1 hour each), 24-hour email response, phone consultations as needed, and alumni network access. We track implementation milestones, refine your KPI dashboard, and help scale improvements.
Is this HRDC claimable?▲
Yes. Husni Halim is an HRDC accredited trainer (TTT ID 11294). Malaysian companies can claim this training under their HRDC levy. Contact us for the SBL-Khas application documents.
Who should attend?▲
Manufacturing supervisors, engineers, operations managers, plant leaders, quality managers. Anyone responsible for process improvement or who directly manages teams on the floor. Limited to 15 participants for hands-on engagement.
Can you run this at our facility?▲
Yes, for larger groups (8+). In-house delivery at your facility across Malaysia. Contact us to discuss dates, location, and customization options.

Reserve Your Spot

May 18–22, 2026  |  De Palma Hotel, Shah Alam  |  Limited to 15 participants

I confirm attendance for all 5 days (May 18–22, 2026) *

Questions?
Husni Halim · Principal Consultant
+60 16-524 1901 · WhatsApp · husnihalim@visiarmada.com