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MAXIMIZING OPERATIONAL POTENTIAL

Advanced Manufacturing Consultancy Sdn. Bhd.

MAXIMISING OPERATIONAL POTENTIAL

Maximising Profitability
Continual Growth
Innovation
Growing the People

Providing capabilities to take


operational teams to next level of
performance

ENGAGED, EMPOWERED AND


SKILLED EMPLOYEES WITH A FOCUS
ON VALUE CREATION

SUSTAINING IMPROVEMENTS
AND CREATING
KAIZEN CULTURE
5

2
1

Imperatives for
Change

Stakeholder
Management

Mobilising Change

Capacity/Skills For
Change

Sustaining the
Change

Operational
Improvement
Consulting &
Training

Accredited
Certification
Programs

YOKI
MONOZUKURI

Soft Skills
& Essential skills

Training Centre
(Ipoh)

NOBODY DOES IT BETTER THAN US

OUR SERVICES

Advanced Manufacturing Consultancy Sdn. Bhd.


helping clients improve performance since 2002

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 relationship
If 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.

Operational Excellence Tools


Developing People
(Training)
Providing Skills for Operators right up to
Operations Directors in:
Lean Manufacturing
Theory of Constraints
Operational Leadership
and more
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 forces
Applying 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

LEAN
SPECIALIST

At your
operational site,
working hands-on
with your staff to
start transforming
it within weeks!

Arrow10-Days
Process
Typical
Operational
Improvement
Activities
Why use graphics
from PowerPointing.com?
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

UNDERSTAND
THE PROBLEM

HANDS-ON
ALL FIVE
DAYS

EXPLOIT THE
CONSTRAINT

Use Quick and Effective problem


solving methods and tools
Identify problem and use prolem
solving tools to immediately
address it
Act on implementation
immediately
PLAN &
IMPLEMENT
IMPROVEMENT

Deep Diving into operations:


Immediate actions to stop
operational problems/constraint
Constraint management activity
done and team learn skills to do so

MONITOR AND
AFFIRM
IMPROVEMENT

Leave an impact in the plant


Plan for sustaining and
maintaining the culture

ACHIEVE
TARGETED
RESULTS

Monitor implementation
and make changes if
necessary
Measure results, assess
and rectify risks and plan
for full implementation

Typical Results Achieved Within a Week

START SEING RESULTS WITHIN


TWO TO THREE WEEKS

Software Solutions
Make Process Improvement Easier, Faster &
Precise
Step 1

Step 2

Film the
process
that you
decide to
analyze

Step 3
Work with
Imporvements

Analyze

Step 4
Secure the
improvements

45%
51%

4%

To do list
Aktivitet

Ans

Tid

Losses
Semiproductivity
Value adding

Quick
No disturbance
You dont loose
any details, the
camera does
not lie.
Repeateble
Communicateable
Objective

Classifies
productivity
Gives: Pre
determed
standard times

Gives:
Imoprovement
suggestions

Quick and easy

Ask for imprrovements


Measurable
Devide into short
and long term
Evaluate corr-ect
priority
Start to eleminate
immidiate losses

Follow up the
analyzed based
improvement
Control the
improvement
Continious
improvements

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

Advanced Manufacturing Consultancy Sdn. Bhd.


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.

Our

SUMMARY OF OUR CLIENTS


ACHIEVEMENTS

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

Company
(Type & Location)

MNC in Singapore

SME in Perak,
Malaysia

MNC in Perak,
Malaysia

Issues

AMC Intervention

Gains

Cannot meet time to


volume
Inventory Control
Problems
High Machine Downtime
Lose of business due to
above factors

TOC Bottleneck
management
Quick-Changeover
Kanban systems
6 months consulting
engagement

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

Very High Lead time


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

Value Stream Mapping


Standardized Work & Cell
concepts
Administrative & Office
Lean
4 months consulting
engagement

Order Processing Lead


Time reduced by 90%
Inventory Reduced by
30%
Reduced manpower
requirement

High rework and scrap


High Inventory
High Machine Downtime

Error Proofing/Pokayoke
Quick Changeover
Standardized Work
Engaged on Training &
project mentoring for
employees

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

$ Value of
Gains

USD
19,000,000

USD
100,000

USD
6,200,000

Company
(Type & Location)

Issues

AMC Intervention

Gains

$ Value of
Gains

USD
2,000,000

MNC in
Thailand

Cannot meet cycle time


target to get competitive
advantage over
competitors

Inventory Management
Six Sigma Process
Controls
Quick Changeover
Engaged for 3 months
consulting

Reduced Lead Time by


20%
Gained increased
market share over time
due to cycle time
advantage

Japanese MNC
Perak, Malaysia

Need to avoid setting up


many auto lines to
increase production
Auto line machines low
productivity

Total Productive
Maintenance (TPM)
OEE improvement
Quick Changeover
Engaged for training and
project mentoring

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

Embarked on continuous
improvement activities

5S, Value Stream


Mapping, setup reduction
Engaged for two weeks
training and projects
mentoring

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

SME in KL,
Malaysia

USD
4,000,000

USD
59,000

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, COO
Carsem 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 Engineering
Belton 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 avoidance
Michael, 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 President
Beyonics 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

AMC clients list


One or more of our services have been rendered to:

Taiwan

Thailand
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

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

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

www.amc-kaizen.com
Email: enquiries@amc-kaizen.com

Advanced Manufacturing Consultancy Sdn. Bhd.


Servicing clients all over Asia since442002

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