AMC Kaizen Maximizing Operational Potential

MAXIMIZING OPERATIONAL POTENTIAL

Advanced Manufacturing Consultancy Sdn. Bhd.

MAXIMISING OPERATIONAL POTENTIAL

Providing capabilities to take operational teams to next level of

performance

Maximising Profitability Continual Growth Innovation Growing the People

ENGAGED, EMPOWERED AND

SKILLED EMPLOYEES WITH A FOCUS

ON VALUE CREATION

Imperatives for Change

Stakeholder Management

Capacity/Skills For Change

Mobilising Change

Sustaining the Change

1

2

3

4

5

SUSTAINING IMPROVEMENTS AND CREATING

KAIZEN CULTURE

YOKI

MONOZUKURI

Operational

Improvement

Consulting &

Training

Training Centre

(Ipoh)

Soft Skills

& Essential skills

Accredited

Certification

Programs

helping clients improve performance since 2002


NOBODY DOES IT BETTER THAN US

OUR SERVICES

OUR OPERATIONAL EXCELLENCE

& KAIZEN SOLUTIONS

Solutions using Toyota Production System

Toyota is considered to possess the worlds most successful operational excellence model. AMC Kaizens solutions based on Toyota production system provides a holistic transformation of an operation using the tested secrets of Toyota.These principles are learnt by AMC Kaizen consultants direct from Japan and learning from Toyota Old-Boys who were part of the development of this system

Solutions Provided: Toyota Kata- Creating a Kaizen Habit and also

Breakthrough Improvements Hoshin Kanri Policy Deployment and strategic

planning Toyota Kaizen methodology Eliminating MUDA

(Waste); MURA (Unevenness); MURI (Overburden) Seven Principles of Toyota Production System The

DNA for sustainable operational improvement culture Genchi Gembutsu Practices- Shop-floor systems for

operational excellence Japan Kaizen Immersion Tour- Learning and

benchmarking trip to Toyota City, Japan

Solutions using Training Within Industry (TWI)

TWI is a proven methodology of enabling supervisors to be in control of shop-floor through Instruction, Job Method Improvement and employee relationshipIf you want your leadership with the right lean job skills: thinking about and improving safety, quality, cost, delivery and productivity of your products or services in the workplace, than TWI is one part of the answer. This is the premier source for Training Within Industry content, which puts the powerful tools of "the most under-rated achievement of the 20th century" into the hands of every person, every where.

Developing People

(Training)

Providing Skills for Operators right up to

Operations Directors in:

Lean Manufacturing

Theory of Constraints

Operational Leadership

and more

Operational Excellence Tools

Lean Manufacturing Tools: Value Stream mapping 6S & Visual Systems Standardized Work Pokayoke/Error Proofing Quick Changeover/SMED Inventory management & Kanbans Layout Optimization Equipment Performance Improvement Lean Diagnostics and much more

Theory of Constraints Tools: 5-Steps Constraints management Drum-Buffer-Rope Inventory Management Throughput accounting Critical Chain Project management TOC Complex Problem Solving

Quality Improvement Tools: SPC & Statistical Improvement Tools DMAIC (Six Sigma) Tools DOE and more

Guerilla Operational Kaizen

Guerilla is defined by Dictionary.Com as a member of an irregular ..and motivated armed force that combats stronger regular forcesApplying this definition to Kaizen, a set of operational improvement skillset is developed in Operational Staff. They go into a warfare against Productivity loss, Quality Loss and Operational Crisis in a focused manner within a short period of time

Guerilla Solutions: Guerilla Operational Kaizen Bootcamp a 4 Day

hands-on training on problem solving Crisis Management The 5-day Kaizen Week methodology

Maximizing Operational Potential

AMC Kaizen has been developing Human Capital at various levels with Lean & Theory of Constraints certifications since 2002. The Lean Master program has been a flagship certification which had helped clients achieve Millions of Dollars in savings. The experience attained has led to several new Operational Excellence certification programs. It caters to all levels of people in an organization. New and proven methodologies and thinking process enables and organization to maximize its operational potentials

Certification Solutions: Certified Operational Excellence

managers Certified Operational Excellence

Supervisors Lean Masters Customer Value Creation Lean Innovation Complex Problem Solving Using TOC

Cause & Effect Critical Chain Projects Management

Quality Management Solutions

ISO & TS certifications helps a company satisfy its customers, meet regulatory requirements, and achieve continual improvement. AMC Kaizens qualified consultants who take a practical down to earth approach, ensuring ISO/TS certification is achieved simply and efficiently. Consulting, Training & audits are provided for smooth implementation and sustained recertification of Quality Systems

Quality Management Solutions: ISO/TS Readiness assessments Awareness & Introductory Training

on Quality Systems TS 16949 Training ISO Training Help in transition from 9001-2008

to 2001-2015

Quality Audits for sustainability Re-certification Audits ISO system establishment and facilitation

of certification by UKAS (United Kingdom Accredition Services.

We guarantee certification within 6 months

Green & Sustainability Solutions

Businesses dont move in the same way particles do, but the actions resulting from business create ripple effects through our social systems, our economic systems and our ecosystems. By focusing on increasing value, decreasing waste and respecting people, Lean is ultimately about transforming how work is done, to make it more efficient and sustainable. Whether you're trying to build a better product or a better world, that's a worthy goal.

Green Solution: Lean Sustainability: Creating a safe,

enduring and profitable operations

Operations Impossible Consulting

LEANSPECIALIST

At your

operational site,

working hands-on

with your staff to

start transforming

it within weeks!

Arrow ProcessWhy use graphics from PowerPointing.com?

MONITOR AND AFFIRM

IMPROVEMENT

Diagnose to understand operational focus area and plan improvement Hands-On Diagnostics takes place while team is given the skills to do so Identify operational constraints Activity planning and target results

Use Quick and Effective problem solving methods and tools Identify problem and use prolem solving tools to immediately address it Act on implementation immediately

Leave an impact in the plant Plan for sustaining and maintaining the culture

Deep Diving into operations: Immediate actions to stop operational problems/constraint Constraint management activity done and team learn skills to do so

Monitor implementation and make changes if necessary

Measure results, assess and rectify risks and plan for full implementation

PLAN & IMPLEMENT

IMPROVEMENT

ACHIEVE TARGETED RESULTS

EXPLOIT THE CONSTRAINT

UNDERSTAND THE PROBLEM

Typical 10-Days Operational

Improvement Activities

HANDS-ON

ALL FIVE

DAYS

Typical Results Achieved Within a Week

START SEING RESULTS WITHIN

TWO TO THREE WEEKS

Make Process Improvement Easier, Faster & Precise

Film the

process

that you

decide to

analyze

Quick

No disturbance

You dont loose

any details, the

camera does

not lie.

Repeateble

Communicat-

eable

Objective

Step 1 Step 2

51%4%

45%

51%4%

45%

Losses

Semi-

productivity

Value adding

Analyze

Classifies

productivity

Gives: Pre

determed

standard times

Gives:

Imoprovement

suggestions

Quick and easy

Step 3

Work with

Imporvem-

ents

Ask for impr-

rovements

Measurable

Devide into short

and long term

Evaluate corr-ect

priority

Start to eleminate

immidiate losses

Aktivitet Ans Tid

To do list

Step 4

Secure the

improvements

Follow up the

analyzed based

improvement

Control the

improvement

Continious

improvements

Software Solutions

Operational Diagnostics

Value Stream Mapping

Understand how much of your processes add Value from a

customer perspective

OUR TRAINING METHODOLOGY

WE TRAIN IN A PRAGMATIC MANNER

Amateurs work until they get it right.

Professionals work until they can't get it

wrong.

AMC Kaizen Training Centre Providing A Fully Equipped Training Facility With Food & Beverage Support For Clients

And Companies In Ipoh

ABOUT US


Company Number: 650118D

Founded in Malaysia in 2002

Web: www.amc-kaizen.com

The company specializes in helping clients improve

operational performance and creating a culture of continuous

improvement. The Japanese term Kaizen, which means

"improving for the better" has been added to the company's

name to describe the driving force behind each consulting

engagement.

Both large multi-nationals (including Fortune 500 companies)

and small businesses all over Asia and also in Europe had

been serviced with tremendous results in operational

improvement.

Reduced Inventory by 50% Reduced Downtime by 30% Reduced Excess Headcount by more than 50% Reduced cycle time by 50% Reduced Scraps & Rework by 15% Increased On Time Delivery from 70% to more than 95% Reduced space utilization by 40% Employee engagement and skill enhancement in

operational excellence

SUMMARY OF OUR CLIENTS

ACHIEVEMENTS

Company (Type & Location)

Issues AMC Intervention Gains$ Value of

Gains

MNC in Singapore

Cannot meet time to volumeInventory Control ProblemsHigh Machine DowntimeLose of business due to above factors

TOC Bottleneck managementQuick-ChangeoverKanban systems6 months consultingengagement

Increase throughput by 21%Reduced Inventory by 70%Reduced Downtime by 40%

USD 19,000,000

SME in Perak, Malaysia

Very High Lead time from order processing to shipment (about 20 days)High Raw Material Inventory

Value Stream MappingStandardized Work & Cell conceptsAdministrative & Office Lean4 months consulting engagement

Order Processing Lead Time reduced by 90%Inventory Reduced by 30% Reduced manpower requirement

USD100,000

MNC in Perak, Malaysia

High rework and scrapHigh InventoryHigh Machine Downtime

Error Proofing/PokayokeQuick Changeover Standardized WorkEngaged on Training & project mentoring for employees

Reduced scrap by 5%Reduced Inventory by 50%Certified set of internal consultants with Lean Mfg. skills

USD6,200,000

Company (Type & Location)

Issues AMC Intervention Gains$ Value of

Gains

MNC inThailand

Cannot meet cycle time target to get competitive advantage over competitors

Inventory ManagementSix Sigma Process ControlsQuick ChangeoverEngaged for 3 months consulting

Reduced Lead Time by 20%Gained increased market share over time due to cycle time advantage

USD 2,000,000

Japanese MNCPerak, Malaysia

Need to avoid setting up many auto lines to increase productionAuto line machines low productivity

Total Productive Maintenance (TPM) OEE improvementQuick ChangeoverEngaged for training and project mentoring

Increased machine OEE to world class levelAvoided capital investment on 3 auto lines

USD4,000,000

SME in KL,Malaysia

Embarked on continuous improvement activities

5S, Value Stream Mapping, setup reductionEngaged for two weeks training and projects mentoring

Reduced machine setup time by 50%Reduced non-value added processesIncreased machine OEE Manpower savings

USD59,000

A supply Chain Turn-Around story which can be retold for ages: Global Lead Time reduced from 150days to below 80days First Drive in the world to sell below 100USD due to cost efficiency

advantage Company-wide Commitment to achieve operational excellence Beat all its competitors through time to market advantage Developed its entire supplier base in achieving a Lean Supply Chain Reduced 8 factories while increasing volume by four fold in 2 years

AMC s Consultant was personally involved as a Corporate Sr. Consultant and team member in driving these results for Seagate Technologies

we find your training and coaching sessions informative, practical and professionally delivered. The choice to go wide to give the big picture before drilling down to select areas delivering highest business impact, is a strategy that serves us wellBesides an average of 30 to 40 percent improvement in set up time, cycle time improvement from 6.5 to 4.2 dayswe are also pleased to see a reduction in critical defects...

SW Woo, COOCarsem M Sdn Bhd.

Lean Manufacturing in general opinion is too BIG and difficult to be achieved. But with AMC as our trainer/consultants Lean has become easily understood by Belton candidates of all levels. Lean has become applicable in Belton

Pongyut, Director of EngineeringBelton Industrial, Thailand

.result is...very ordinary people here ( Production Supervisors, Engineers), moving on very ordinary projects ( Poka--yoke, UPH improvement, Kanban system, etc) for some VERY extra-ordinary results. I am very pleased that so much dollars and cents has been saved with a lot of simple, sensible and stellar projects.

Keep up the good work and I am so proud with all of you.

Comment of Managing Director of Finisar to AMC Lean Master Candidates

Lean Manufacturing came at the right time to save millions of dollars for us in capital avoidanceMichael, Lean/Engineering Manager

MSP, Ipoh (NSK Group)

Lean Manufacturing is an effective tool to reduce wastage, optimize capacities & reduce costs.AMCs course taught us the effectiveness of various Lean Tools.The course is very interactive and the simulation games are very interesting. The course instructors use their

extensive industrial experience to elaborate important points and make participants understand the key points

Roger Goh, Vice PresidentBeyonics Precision, Johore Bahru

Very good projects and excellent savings, nothing should stop us from standardizing these actions across the floor immediately ..Innovex Thailand, VP of Quality

and Operations

...Ramesh Victor has demonstrated the ability of going into problem factories, and quickly turn around their manufacturing operations. Approximately 7 people in the whole of Seagate 45,000 possessed this skill set

Richard C. Craven B.Eng, MSc, MBA, CEng, MIMechE

Seagate Supplier Lean Manager for Europe & Asia

Utterly fantastic...without lean implementation at...we would not have met the Barracuda ATA- IV schedules

Matt Johnen. VP Asia Materials (Seagate)

AMC clients list

One or more of our services have been rendered to:

Malaysia General Electric, JB Komag, Pen, JB, Sarawak Eng Teknologi, Penang MMI Johore Bahru Beyonics Precision JB Wong Engineering, Kulim NSK, Malaysia MSP, Ipoh Balda Thong Fook, Ipoh Finisar Ipoh Hovid Pharmaceuticals, Ipoh Ryco Hydraulics, Kulim Crest Ultrasonic, Perai Camfil Farr, Batu Gajah Perak Community Specialist

Hospital Schaefer Kalk Imerys Siegwerk Pantai Hospital Hartalega K1

Malaysia Poly Plus, Perai Rhombus, Perai H & P, Perai Automotive Lighting, Penang Smart Modular, Perai Knowles Altum, JB Juason Plastic, Perai Balda (Mold Tool Room) Trane (Aircon) Mapa (Hutchinson Group) Rosa Pasadena (Hotel) Carsem Semiconductor PSC Casting HCM-Hygenic Corporation MEMC (silicon wafer) Unisem Sun Edison First Solar Kenanga Investment Bank Dynacraft

Thailand Minebea (NMB) Innovex Belton Beyonics Compart Fabrinet Agere Magnecomp

Singapore Seksun Corp Philips (Alliance with Gemba USA)

India Public seminars for various clients Royal Enfield Titan (Tata Group) Trident

Japan Furukawa

Taiwan Ambit Nanotech

China Seksun, Suzhou MMI, Wuxi Belton, Shenzhen Belton, Wuxi Compart Magnecomp Optimal Snap On Broadway Shanghai

Indonesia Philips (Alliance with Gemba USA)

Others / global Seagate Technologies

AMC clients list

One or more of our services have been rendered to:

AMC HAS SUCCESSFULLY HELPED COMPANIES IN THEIR JOURNEY OF OPERATIONAL EXCELLENCE.WE HAVE THE EXPERTISE: WE KNOW HOW IT IS DONE!WE HAVE THE EXPERIENCE: WE HAVE DONE IT BEFORE!We can help you achieve your Goals towards establishing a culture of operational excellence


Servicing clients all over Asia since 200244

www.amc-kaizen.comEmail: [email protected]

Documents

AMC Kaizen Maximizing Operational Potential