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"Estimate & Drawings"

IDEAS FOR COST REDUCTION & PROFITABILITY INCREASE IN MANUFACTURING (15,16 JAN 2025)

Please call 012-588 2728

 email to pearl-otc@outlook.com

 

FACE-TO-FACE PUBLIC PROGRAM

IDEAS FOR COST REDUCTION &

PROFITABILITY INCREASE IN MANUFACTURING

Venue : Wyndham Grand Bangsar Kuala Lumpur Hotel      (SBL Khas / HRD Corp Claimable Course)

Date : 15 Jan 2025 (Wed)  |  9am – 5pm                       By Selvaraj

   16 Jan 2025 (Thu)   |  9am – 5pm                              .   

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INTRODUCTION:

In this compact but value filled workshop, we look at the right strategies on how to reduce cost in a structured manner.

 

Cost reduction is so much more than just cost control and cost cutting. True cost management is about being aware of costs, seeking to reduce them through good design and efficient operating practices whilst taking continuing action on overspending. MCPD (Manufacturing Cost Policy Deployment) addresses how to handle cost reduction challenges in a structured and proven approach.

 

Lean approach shows a systematic method to identify and eliminate wastes (non-value added activity) rather than direct cost reduction which might impact our operations and services adversely.  

 

COURSE OBJECTIVES:

1.       Understand what is MCPD (Manufacturing Cost Policy Deployment).

2.       How to continuously move towards being a profitable organization under every conceivable scenario?

3.       Cost reduction vs waste reduction.

4.       How to Identify areas that have potential for waste reduction?

5.       Setting priorities for waste reduction step by step in a systematic manner.

6.       Becoming aware of the current value stream and bottleneck areas for cutting costs.

7.       Establishing methodologies for planning and implementing performance measurement.

8.       Methods to maintain the cost reduction gains and have continuous improvement.

9.       How can the Six Sigma DMAIC approach lower costs and improve quality?

10.    How to use the 11 pillars of Industry 4.0 for cost reduction? 

 

INTENDED AUDIENCE:

1.       CEO

2.       Directors

3.       Managers

4.       Section Heads

5.       Engineers and Executives

6.       Suitable for all Manufacturing, Business and Service organization 

 

 METHODOLOGY:

1.       The workshop is a mixture of presentation with personal examples, assessment, discussions and group activities.

2.       Training will be conducted online using Virtual Platform.

3.       Activities will be given throughout the training for better understanding. 

4.       Participants to develop customized cost reduction strategy with inputs from facilitator.  

  

OUTLINE OF WORKSHOP

DAY 1 (9.00am—5.00pm)

 

1. Introduction – the cost management process

i. The risks of poor cost control

ii. The importance of cost awareness

iii. The importance of cost reduction

iv. Cost management – the key aspects

 

2. Understanding of the MCPD system

i. Directions

ii. Productivity goals

iii. External & internal manufacturing profits

 

3. Scenarios and strategies of the MCPD system

i. Increase or decrease in sales

ii. Maximizing outputs

iii. Minimizing inputs

iv. Variable cost efficiency

v. Fixed cost efficiency

 

4. Manufacturing Cost Improvement (MCI) and OEE – maximizing outputs

i. Scrap reduction

ii. Eliminating bottleneck

iii. Cycle time reduction

iv. Increasing availability

v. Breakdown reduction

vi. Setup and adjustment reduction

 

5. MCI improvement through reducing fixed and variable costs – minimizing inputs

i. Raw material

ii. Utility

iii. Labor

iv. Environment

 

6. Methods for gathering and analyzing the necessary data for cutting costs

i. What are the 7 wastes and how to identify them?

ii. Value add vs non-value add

iii. Lean assessment

iv. Lean indicators

v. VSM – Value Stream Maps

 

 

DAY 2 (9.00am—5.00pm)

 

7. Methods of cutting cost by reorganizing our processes

i. JIT – Just in time

ii. Kanban systems

iii. Quick changeover

iv. Standardized Work

v. Downtime reduction with TPM (Total Productive Maintenance)

vi. Lead time reduction

vii. Poka Yoke (mistake proofing)

viii. Utilizing the 8th waste – utilizing people’s creativity

ix. Case studies

 

8. Using Six Sigma to reduce costs

i. How to choose the right DMAIC projects?

ii. Process capability studies

iii. SPC for data dashboard and to establish control

iv. Statistical data analysis techniques

v. Case studies

 

9. How to use the 11 pillars of Industry 4.0 for cost reduction?

i. Data dashboards for performance monitoring

ii. Disruptive technologies

iii. Digital transformation requirements for Industry 4.0

iv. Case studies

 

10. Cost reduction culture

i. The need for cost reports

ii. What measures can be used to identify over-spends as early as possible

iii. Cost control performance measures and ratios

 

11. Action plan – participants and trainer to develop customized cost reduction strategy for each participating organization.

 

 

 

 

** Certificate of attendance will be awarded for those who completed the course

 

ABOUT THE FACILITATOR

 

Selvaraj is a highly qualified technical trainer in the areas of Continuous Improvement and Quality Excellence. He believes in interactive and fun filled training. His method of training is sharing rather than lecturing. With 23 years of experience in the field of Manufacturing Improvement & Quality Excellence covering areas of Design, Material Selection, Tooling, Machine & Process Engineering, Production and Supply Chain Management, Selvaraj B uses lots of real life examples. Selvaraj B started his career in 1989 as a Mechanical Engineer and in 23 years, has worked in 3 MNC companies that are World Class, i.e. Matsushita (Japanese), Robert Bosch (German) and Entegris (American) up to the level of an Operations Manager. Selvaraj B is a certified HRDF trainer. His strength is combining the intricacies and details of technical training with highly humorous anecdotes for maximum training effectiveness.  

 

AMONG HIS NOTABLE ACHIEVEMENTS ARE:

1. Leading Gold Medal winning teams to NPC conventions – 1995 - 2002

2. Certified MTM and Ergonomics practitioner - 1997

3. Tooling & plastic parts design standardization - 2000

4. Awarded best Six Sigma Champion award in 2006 for promoting successful Sigma projects – 2006

5. Certified Trainer with Napoleon Hill International - 2007

6. Certified Lean Sigma Champion - 2010

7. Competent Communicator & Humorous Speech Division N Champion in Toastmasters International – 2012

8. Certified Six Sigma Master Black Belt - 2016

9. Member of the Society of Plastics Engineers

10. Member of the Institute of Engineers Malaysia

11. Certified NLP Practitioner - 2016

12. Certified VDI Quality Systems auditor - 1997

13. Certified Industry 4.0 Professional accredited by the US-based

International Institute of Executive Careers™ (IIEC)

 

AMONG HIS NOTABLE IMPROVEMENTS PROJECTS ARE:

1. Consolidating the Plastic Injection Moulding sections into 1 department & leading it – Bosch Bayan Lepas

2. Motivating and guiding numerous scrap reduction & quality improvement teams – Bosch Bayan Lepas, Automotive Lighting Bayan Lepas

3. Reduction of manufacturing lead time from 28 days to 3 days – Entegris

4. Cycle time reduction projects – Bosch, Entegris

5. Lean improvement projects – Signature Kitchen Sdn. Bhd. KL, Anshin Precision Sdn. Bhd. Shah Alam, Silverstone Berhad Taiping.

6. Starting a new factory of 200 headcount for Silicone Wafer Process Carrier comprising of Manufacturing, Maintenance, Engineering, Tooling, Production Planning & Continuous Improvement Department – Entegris Kulim Hi-Tech.

7. Guiding and inspiring numerous quality improvement and cost reduction teams to State level and National level competition and recognition.

8. Setting up & developing a World Class Manufacturing team for clean room fittings manufacturing – Entegris Kulim Hi-Tech

 

 (SBL Khas / HRD Corp Claimable Course)

TRAINING FEE

2 days Face-to-Face Public Program

RM 2,250.00/pax    (excluded 8% SST)

Group Registration: Register 3 participants from the same organization, the 4th participant is FREE.
(Buy 3 Get 1 Free) if Register before 7 Nov 2025. Please act fast to grab your favourite training program!

 

We hope you find it informative and interesting and we look forward to seeing you soon.

Please act fast to grab your favorite training program! Please call 012-588 2728

or email to pearl-otc@outlook.com

 

Do forward this email to all your friends and colleagues who might be interested to attend these programs

 

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Thanks

Regards

Pearl

by "pearl@otcsb.com.my" <pearl@otcsb.com.my> - 07:52 - 6 Nov 2024