BY : EDDY YEOW

My Journey in Lean Manufacturing

My Journey

Biz venture

Sales

My SKILLs

I am a decisive Lean Manufacturing Professional equipped with hands-on Lean Manufacturing tools & techniques such as Kanban , Work Simplification, Line Balancing, Dynamic 5 S, Re-design Work Station, Poka Yoke, Andon, SMED, Pull & Push system, Visual Management, JIT production, Cycle Time Analysis, Total Productive Maintenance, Cellular Manufacturing & Single Piece Flow.

With my problem solving skills & systematic approach using relevant methods like DMAIC, FMEA, 8 Ds & QCC problem solving story, I am able to coach & mentor teams in transforming the organization into a Learning Organization.

Also, I am very careful in ensuring company organization, complying with the quality, safety, health & environment management standards such as ISO 9000, ISO 14000, TS 16949, HACCP, HALAL & SHE compliance.

I have 22 years working experiences in Manufacturing environment, 5 years R n D and balance 17 years in operation ie. overseeing production, maintenance, quality control, store & logistics.

I am a hands-on Lean Champion in Sharp-Roxy with 10 years’ experience involve in Lean and CI (Continuous Improvement) activities for production shop floor. For past 10 years, i have involved with more than 8 CI projects with cost saving up to RM 1.8 million a year. Where else, in the subsequent Companies, I have applied what I have learned, to coach & mentor teams in their CI activities.

My SKILLs

I have in-depth experience, working with multi-national & SMI companies, understand multi-functional and multi-culture teams behavior, proven experience to execute lean manufacturing strategies, improvement initiatives and operations with various company management style & size.

In addition, I have excellence knowledge and experience in Project Management, Scheduling, Coordinating, Negotiation, On Time Delivery & Problem Solving with contractors/suppliers/machine makers across the world.

As I am a graduate from Mechanical & Automotive Engineering and in Food Manufacturing Management, I am resourceful to to the organization knowledge needs whenever necessary.

Besides, I have excellence computer and data analysis skill in Microsoft Excel, Words, Powerpoint & ERP system ie. SAP & M3.

Nevertheless, I am proficient in several language Malay, English and Chinese (Mandarin, Cantonese, Hokkien), which enable me to communicate directly to all levels of people.

I am a trustworthy, dedicated, diligent, persistent & sincere person with high integrity, strong team work and cooperation.

History of Lean Manufacturing

Firstly, introduce by Henry Ford on the ‘continuous flow’ mass production for cars assembly line using the push system.

After then, Toyota improvise with a pull system base on customer demand, which used ‘Just in Time’ manufacturing method to increase efficiency & reduce inventory, which is now called ‘Toyota Production System’

What is Leans Manufacturing ?

Leans Manufacturing is a systematic method for elimination of waste (Muda) & maximizing customer value in the products & services within a manufacturing process.

Lean also takes into account waste created through overburden (Muri).

And waste created through unevenness/variations in work loads (Mura).

What is the meaning of Waste & Value ?

Waste means……Waste activity that does not add value to the product

& services.

Value means……Any action or process that a customer would be

willing to pay for.

Type of Waste to be Monitor

Waste created by ….Unnecessary Transfering or transportationInventory – Too high RM, WIP or FG stocksUnnecessary Motion activityUnnecesssary & high Waiting time Overprocessing – Repeated processOverproductionDefectsWorkforce

Lean Manufaturing Process

Stage 1 – Identify Waste Must have the commitment to do Kaizen Use VSM to connect the flow of material till F/Good to identify waste

Stage 2 – Analyze the Waste & Find the Root Cause Use Root cause Analysis – Brainstorming or Fish bone diagram to

identify the root cause

Stage 3 – Solve the Root Cause & Repeat the Cycle Decide what you must do to fix the issue to create more efficiency

Tools to Reduce Waste

Just in Time – Pull system to minimize stock & resources

Kanban – Signal or Visual CardPoka Yoke – Do it right the first timeSMED – Quick & efficient changeover of Die5 S system – Tools, equipment & workplace are in

order with a good level of standardizationEtc.

Before After

Island system

Longer/heavier traffic of transfering High WIP Heavier Motion movement Longer waiting time Overprocessing due to sorting &

rework frm over stock Overproduction Defects from idling stocks

Train system

Lesser traffic/shorter transfering

Lower WIP Easier Motion movement Shorter waiting time No more repeating job No more overproduction No more unnecessary defects

Eg. of Lean practises

1 652 3 4 87

1

3

2 5

4

Sharp Roxy Achievements

Reduce headcount within 2 years in Production shop floor from 200 to 100 people whilst maintaining the quality & productivity of the product.

Maintaining industrial harmony within employees, employers & the trade union during the reduction of the head count.

Certification of ISO 14000 Recognition as Super 5S plant by NPC Japanese

consultant QCC presenter in JAPAN QCC convention Trained in Japan & Germany for Project completion

Sharp Roxy Lean projects & saving ….

Headcount reduction from 200 to 100 with cost saving

up to about Rm 1.8 million a year by applying Lean

approach….1. Train system for Cond. Pipe fixing = Rm 250 k (As in slide 12)

2. Clinching replace spot weld to cabinet = Rm 280k

3. New Door Cap design = Rm 180 k

4. New Door Liner design = Rm 480 k (Presented in Japan)

5. Simplify Door cap Ass’y = Rm 45 k

6. New Cooling Line layout = Rm 450

7. Real Time Monitoring on Output Variance = Rm 90 k

8. Others = Rm 25 k

TOTAL COST SAVING = RM 1.8 Million

NESTLE Achievements

Executive Diploma of Manufacturing Management - As a non-Food Technologist to work & study and pass all the examination papers.

Lead, coach & mentor a ‘weekly rotating shift’ operators to deliver daily KPIs ie on Quality, Speed, Cost & People during the Daily Review Meeting.

Coach a team projects using Lean Six Sigma to reduce OPP changing time using SMED approach & present it in the SGIA bi-monthly presentation to the top management. Cost saving up to = Rm 20 k

Pecca Leather Achievements

Launch & implement 5 S work culture with rewards given by monthly cross audit by the HODs.

Keep track all small 5 S practices by the operators with ‘Best Employee of the Month’ recognition.

Went to Nepal & Sabah for operators recruitment as part of expenses reduction.

Coach a special ‘Task Force’ teams apply Lean techniques by changing layout from Linear flow layout to a Cellular flow layout with cost saving of Rm 35 k

ORIENTAL Achievements

Improve Organization Efficiency by saving annually up to Rm 240 k Re-design organization controls systematically with ownership Implement 5 S work culture Ensure all quality management system are complied ie. ISO/HACCP/HALAL Comply safety & environment rules by regulatory bodies ie. DOE & DOSH

and save Company from penalty approximately = Rm 20 k Save water usage & leaking issue = Rm 100 k Save Air Cond. repairing cost by using internal technician = Rm 120 k Increase Production volume by 28 % with strategies as below implemented Shorter lead time to complete new line set-up by add. vol. of Rm 38,000 k Implement TPM practices with higher annual volume of Rm 17,000 k # Improve Leaders & Technician cooperation & teamwork by on-site coaching applying GEMBA

# Improve ad-hoc Planning to weekly Planning by Visual Management

# Improve operators working time by enforcing ‘Break Time’ check in a few check point daily

# Implement OEE analysis daily by HODs to have a better Goal Alignment

# Improve on outsource repair time by supporting Supplier on Lean practices

# Establish Spare Part Room for the availability of machine parts

# Restoration program to lengthen life span of machine run time

# Daily Maintenance Meeting to close Job Open promptly

Additional Volume = RM 55, 000 K … 28% up vs to Annual Sales

THANK YOU

THE END