Course Overview
Training and Learning (T&L) program for Foundation of HVM for a Technician are necessary part of preparing new and current employees for the technical and cultural aspects of working in a high-volume manufacturing (HVM) operation or plant.
Every company has its own unique ways of performing tasks and handling day-to-day operations, and T&L can turn into a long, drawn-out process while everything is explained. Utilize this program to start digitizing your HVM operation employees maintain their focus, producing high quality products, world-class high productivity level and positive mind-set.
Who Should Attend?
- Unemployed graduates who have obtained SPM/Diploma / Degree
- School leavers aged between 18 to 40 years with school/exam certificate
- Retrenched workers aged between 18 to 55 years who are registered with Employment Insurance System (EIS)
Pre-requisite
Come with open-minded and ready to embrace change
Course Outlines
Day 1
Lean supply chain management is about promoting efficiency by removing unwanted or wasted components from a process. This process is most often applied to manufacturing, where supplies can be ordered as they’re needed rather than holding a lot of inventory as back stock.
- Learning Objective and key takeaways
- Mission, Vision, Goals – Ice breaking session
- Lean – The history
- Lean – Ground Rule (Make it simple!)
- What is Lean?
- Why Lean for HVM operation?
- What is Supply Chain?
- What is Waste?
- Muda, Muri, Mura
- 8 Types of Waste
- Wasted Human Talent
- Defects
- Inventory
- Overproduction
- Waiting time
- Motion
- Transportation time
- Over processing
- Lean house framework
- JIT
- Jidoka
- Stability
- Just in Time (JIT)
- Tact Time
- Cycle Time
- Lead Time
- Capacity
- Machine/Workstation capacity
- Production line/Cell capacity
- Bottleneck
- Throughput rate
- Utilization rate
- Planning
- Manpower planning
- Machines planning
- Build plan
- Ship plan
- Material planning
- Yield and Unyielded planning
- Inventory management
- Inventory costing , count, type
- 80:20 Rule (Analysis)
- Kanban concepts
- Pull system
- Basic types
- Andon system operations
- Standardize work
- Value Stream Mapping (VSM)
Day 2
SPC or statistical process control is a statistically-based family of tools used to monitor, control, and improve processes. Statistical Process Control (SPC) training can be time consuming and frustrating because of the complex nature of the statistics underlying SPC control charts. Basic SPC is a comprehensive online SPC training course for engineers, operators, and technicians that makes understanding and applying statistical process control (SPC) concepts easy.
- What is SPC?
- What are Process Variations?
- Introduction to Variation
- Measuring Variation
- Patterns of Variation
- Measures of Variation
- What is SPC Control Chart?
- What a Control Chart Looks Like
- Interpreting Control Charts & Taking Action
- Types of Control Charts
- Control chart variables
- Control chart pattern
- Why SPC is important in HVM?
- How the SPC process flow works?
- Identify defined process
- Identify measurable attributes of process
- Further control
- Who is the Person in Charge (PIC)?
Day 3
This course teaches the optimal planning and writing process to convey technical and complex information effectively. And, participant will learn how to write reports more efficiently, saving time and reducing frustration. The course also includes to review final report and ensure future reports are strong.
- Project Management for Technical Report Writing
- Teamwork and Logistics for Major Reports
- Estimating Your Development Time
- Generate the Blueprint
- Action Oriented Technical Reporting
- Organize the Sections and Components
- The Numbering System
- Content from Existing Documents, Systems and Experts
- Clarity in Reporting – Use of Emphasis, Concise Active Voice
- Abbreviations, Acronyms and Double Meanings
- Why Readers Become Confused
- One Person’s Jargon Is Another Person’s Vocab
- Technical Report Tones for Style and Impact
- Using Bullet Points and List
- The Art of Managing Redundancy
- Visual Literacy – Using Images, Charts, Graphs, Pictures, Diagrams, Sketches, Tables
- Reducing the Access Time to Critical Information
- Drafts to Final Copies – Reviewing, Editing and Testing
- How Good is Your Proofreading?
- Writing Impressive Conclusions
- Writing Precise Executive Summaries
- Using Writing/Word Software Effectively for Spelling, Punctuations, Grammar, Structure, Vocabulary, Homonyms
- Technical Report Writing Productivity
Day 4
KAIZEN is a Japanese word meaning gradual, orderly, change for better, continuous improvement. The KAIZEN business strategy involves everyone in an organization working together to make improvements without large capital investments. By improving standardized programmes and processes, kaizen aims to eliminate waste called Lean Manufacturing.
Kaizen is a daily process, the purpose of which goes beyond simple productivity improvement. Kaizen also teaches people how to perform experiments on their work using the method and how to learn to spot and eliminate waste in business processes and the process suggests a humanized approach to workers and to increasing productivity.
- Concepts and Principles of Kaizen
- Kaizen Application Insight
- Crucial Implementation Issues and Strategies
- Maintaining Kaizen Implementation
- Role of Management
- Planning a Kaizen Continuous Improvement Programme
- Change Management
- Tailoring the Culture to Kaizen
- Kaizen Tools
- Selecting and Handling Projects
- Identifying Teams to Implement Kaizen
- The Roles of Team Members
- Performance Metrics
- Successful Kaizen Implementation
- Kaizen Quality Improvement Tools
- 7QC Tools and their Application
- Check Sheet
- Pareto Chart, Histogram, Scatter Diagram
- Process Map
- Cause and Effect Diagram
- Process Map
- Control Chart
- Kaizen Week Preparation
- General Kaizen Week Framework
- Facilitation Keys
- Kaizen Team Rules
- Kaizen Week Schedule
- Module 5: 7 Types of Waste
- Overproduction
- Overprocessing
- Waiting
- Motion
- Transportation
- Inventory
- Rework
- Kaizen Tools and Techniques
- Change Management
- Leadership
- Tailoring Culture
- Aligning Improvement Programs to Business Objectives
- Introduction to Value Street Mapping
- Selecting and Managing Projects
- Developing a Kaizen Roadmap
- Role of the Kaizen Leader
- Planning and Organising Effective Kaizen Events
Day 5
Poka-Yoke training is an important component of quality management initiatives for an enterprise to ensure they adhere to Zero Quality Control (ZQC) approach.
This approach is usually used with processes that have catastrophic consequences in service failures. Participants taking up this Poka-Yoke training will learn about Poka-Yoke, Zero Defect Quality, Cause of Defects, Types of Human Errors, Waste, 3 rules of Poka-Yoke, and more.
- What is Poka-Yoke?
- History of Poka-Yoke
- Zero Defect Quality
- What is Zero Defect Quality?
- Components of Zero Defect Quality
- Causes of Defects
- Types of Human Errors
- Types of Inspection
- Zero Defect Quality – Point of Origin Inspection
- Zero Defect Quality – 100% Audit Checks
- Zero Defect Quality – Immediate Feedback
- Zero Defect Quality – Poka-Yoke
- Waste
- Poka-Yoke - 6 Principles
- Poka-Yoke System Approaches
- System Approaches for Poka-Yoke
- Poka-yoke Methods
- Poka-Yoke Methods - Contact
- Poka-Yoke Methods - Counting
- Poka-Yoke Methods – Motion Sequence
- Poka-Yoke Guidelines
- Poka-Yoke Implementation
- 3 Rules Of Poka-Yoke
- Poka-Yoke Exercise