Once the basic problem-solving or quality improvement process is understood, the addition of quality tools can make the process proceed more quickly and systematically. 7 QC Tools can be used by any professional to ease the quality improvement process: flowcharts, check sheets, Pareto diagrams, cause and effect diagrams, histograms, scatter diagrams, and control charts. The concept behind the seven basic tools came from Kaoru Ishikawa, a renowned quality expert from Japan. According to Ishikawa, 95% of quality-related problems can be resolved with these basic tools. To the key to successful problem resolution is the ability to identify the problem, use the appropriate tools based on the nature of the problem and communicate the solution quickly to others. At the end of this course, participants will be able to apply the seven basic tools at their workplace.

The 5S HOUSEKEEPING is a structured program to systematically achieve total organization cleanliness and standardization in the workplace. 5S Housekeeping is based on the Japanese housekeeping practice. 5S is necessary to ensure a clean and orderly working environment with a highly visible management. The work environment determines how fast and how efficiently work could be done. Goods produce in a clean and well-organized environment also tends to be of better quality. In a company where 5S are seriously practiced, the numbers of defect products will be relatively lower that of a disorganized company. Productivity will therefore be higher.

5S improves safety, work efficiency, improves productivity and establishes a sense of ownership. And a well organized workplace motivates people. Good housekeeping can be extremely important in keeping an operation safe. Implementations of 5S need to be checked and audited from time to time to make sure it’s well implemented. This course is designed to equip participants with the knowledge of 5S and the auditing techniques.

At the end of the course, participant able to:

• practice step-by-step approach to 5S principles and techniques
• relate the importance of improving productivity in the organization through 5S good housekeeping and waste elimination.
• identify waste in the organization and take actions to elimination them.
• acquire sufficient knowledge and skills for improving their workplace through 5S good housekeeping practices.
• gain the proper auditing skills and techniques.

Total Productive Maintenance (or Total Productive Manufacturing) is a continuous improvement strategy that embraces all aspects of an organization. The father of TPM was Seiichi Nakajima, who pioneered the approach in Japan and exerted a major influence over the economic progress made by Japanese manufacturers from the late 1970’s. TPM is based on the experience that equipment and process problems are the root cause of many of the unplanned events that reinforce a reactive Management style. Delivering reliable equipment alone, however is not enough to deliver world-class company performance. ‘Maintenance’ should encompass monitoring and improving the total integrity of the organization through the people who add value – production and maintenance personnel alike.

The Total Quality Management (TQM) philosophy is a holistic approach for addressing overall organizational performance, central to the philosophy is that all organizational functions are focused on meeting customer needs and organizational objectives. This company-wide approach views organizations as a collection of processes that must be continuously improved by incorporating the knowledge, skills and experiences of all workers.

This is achieved through understanding and implementing the seven principles of TQM. TQM is “total” because it encompasses everything an organization does – all its products, processes and people at every level of the organization all the time. The focus of TQM is on continuous improvement, elimination of waste and reduction of cost, the strengthening of relationships with key suppliers and customers, towards improving its products and services.

This course will introduce participants to the various costs of quality. Cost of Quality is an excellent continuous improvement management tool. Cost of Quality can be used effectively to identify, prioritize and then track projects by breaking down quality costs into the four standard categories of prevention, inspection, internal and external failure. Quality cost data can be collected through a cost of quality assessment process. This course presents an overview of the process.

This course enable participant to:

• understand the elements and definitions of the Cost of Quality
• understand the benefits of Cost of Quality
• develop and implement strategic quality action to improve cost saving
• understand about tools and strategies to reduce the cost of non-conformance in the workplace

Mistake Proofing/Poka Yoke is a mistake proofing tool where its’ purpose is to minimize dependency on humans. Simple tools are used, resulting in the freeing of worker’s time and mind to pursue creative, value-added and problem solving activities. Shingeo Shingo an industrial engineer at Toyota, developed this tool that is now extensively used for achieving Zero Defects. The philosophy is to prevent mistakes before they occur and the minimization of quality control inspections, bringing about lower costs.

At the end of this training session, participants should be able to:

• explain Mistake Proofing /Poka Yoke
• understand the various Mistake Proofing/Poka Yoke techniques and how these techniques can apply in their processes

Kaizen in Japanese simply means change (kai) for the better (zen), although the term has become associated with the philosophy of gradual, orderly and continuous improvement involving everyone in the organization. Kaizen is implemented by lower management and workers but relies heavily on Senior Management support and direction to develop the necessary culture that challenges workers to be creative in finding solutions to problems, hopefully without the need for hard cash.

The program has been designed to:

• understand the underlying concepts and principles behind Kaizen
• know the tools used in Kaizen
• teach participants how to learn from the environment around and how to find simple and low cost solutions to seemingly complex problems.
• teach participants the common sense and low cost approach to improvement
• know managements role and accountability for successful implementation

This course is designed for workers, operators and supervisor to create a general awareness on quality. Most of the workers, operator and supervisors are the main or important work force working in the production line in the organization. They need to be educated with the concept, principles and the important of the quality in the organization.

At the end of the course, participants able to:

• understand the concept of quality
• understand the important of quality in reducing cost in the organization
• identify and solve quality problem in the workplace
• understand operator / workers role in quality concept

The business environment today is getting more and more competitive and challenging. Manufacturers are under ever increasing pressure to Improve Customer Satisfaction, Improve Quality, Reduce Scrap, Reduce Product Cost, Reduce Cycle time, Reduce Inventories and Improve Overall Productivity. This Quality Control Circles (QCC) provides an opportunity to the direct labor to work together with their supervisors using QCC Tools and Techniques to solve problems in a systematic approach.

This course is designed to provide participant with the basic understanding of the followings to:

• provide understanding on QCC concept and techniques
• enable participants to implement QCC activities in the organization
• provide both understanding and application of the tools for analyzing and interpreting data for problem solving and process control

There is area an estimated 10,000 forklift drivers operating in Malaysia and an average of 3 are killed and several hundreds injured in accidents each year. In addition, most forklifts are damaged due to lack of knowledge and skills on the correct techniques of forklift driving and maintenance. Our safety training programs can be customized to meet your organization’s special needs. We can individualize program content by incorporating photographs of your site into the training program, specifically targeting and emphasizing areas of needed improvement.

Upon completion of the workshop, participants able to:

• acquire proper skills required to drive a forklift and practice safe forklift driving skills
• learn appropriate loading and stacking skills and plant traffic rules
• assessment on competency through theoretical and practical examination
• learn the proper maintenance procedures of forklifts

Most of the internal quality auditors have been trained on what corrective action is and how to take corrective action but very seldom the process owner (auditee) are trained on how to determine appropriate corrective action. This course will provide an introduction of internal audit, tools and techniques used in managing an effective corrective action.

• To provide a practical approach for managing corrective action that enables an appropriate action to be taken to eliminate the cause of non-conformities.
• To provide a guidance and step by step approach in taking effective corrective action and determine the needs of prevention action.

This module provides an introduction to the principles and concepts of risk and risk management. It explores the history of risk management to help gain an understanding of current drivers of enterprise risk management, as well as the development and impact of international standards. This module requires participants to have hands on in risk management and where site assessment is required for exposure in actual risk identification.