KAIZEN in MALAYSIA

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KAIZEN Knowledge

Sharing Seminar 2017

KENYA

Rosmi AbdullahApril 26 – 28 2017

Malaysia Productivity Corporation

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About MPC

MPC Flagship Products and Partnership Programme

KAIZEN INITIATIVE - MPC System Development

Programme

Results from Implementation of Kaizen

Sustainability of KAIZEN Programmes

AGENDA

1966 21st Feb 20081991

National

Productivity Centre

National Productivity

Corporation

Malaysia

Productivity

Corporation

A Statutory Body Under Ministry of International Trade and Industry(MITI)

Introduction

Management Training& Advisory Services

Research & Best Practices

Competitiveness & High Impact Productivity3

Kuala Terengganu

Kota Bharu

Head Quarters, Petaling Jaya

PJ8 Tower, Petaling Jaya

Johor Bharu

Kuantan

Kepala Batas

Kuching

Kota Kinabalu

Strategically

Located

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Core Values

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RR

EI

BE

GC

KM

• Monitor, review, assess and provide recommendations for policy / regulatory changes, and on new regulations to

enhance national productivity and innovation.

• Provide support for existing committees on facilitating businesses.

• Improve innovation at companies by creating and implementing eco systems to address the entire innovation value

chain.

• Measure and certify companies and showcase role models to spur competition and set best practices for others to

emulate.

• Set and enhance innovation standards with the “Health “ check framework.

• Develop global and national macroeconomic knowledge base on Malaysia’s competitiveness.

• Expand focus to state level benchmarking and support international benchmarking for regulatory review.

• Create knowledge base with productivity and industry reports and provide fact base on productivity and

innovation.

• Support Regulatory Review and Enterprise Innovation with research output.

Regulatory Review

Enterprise Innovation

Business Excellence

Global Competitiveness

Knowledge Management

FOCUS AREAS OF MPC Since August 9th , 2010

MPC FLAGSHIP PRODUCTS

ICC /QCC

New Zealand

UNIKAustralia EU

SingaporeThailand

Indonesia

TaiwanAgensi Inovasi Malaysia

Republic of Korea

LOCAL AND INTERNATIONAL STRATEGIC PARTNERS

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Business Environment

Smart Regulation

Knowledge Management

Global Competitiveness

Promote Good Regulatory

Practice (GRP)to enhance quality of

existing & new regulations

Productivity statistics for

organisational and national

development

Monitor Malaysia’s competitiveness and

address areas for improvement

Work Place Productivity

Talent Development

Process Innovation

Recognition Programs

Capacity development programs on productivity

enhancement tools

Consulting & advisory on improving

organizational productivity

Best practices sharing

platforms for process

innovation initiatives

Certify & recognize

outstanding individuals &

excellent organisations

Systems Development

Programs to Enhance National, Sectoral and Enterprise Productivity

1.0 ENTERPRISE INNOVATION INTERVATION PROGRAMME (EIIP) SYSTEM DEVELOPMENT PROGRAMME

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Business Diagnostic (Measurement Metric)

Process Metric

Time Cost Quality Output Metrics Process

Organisational Metrics:

Deployment Morale Metrics Productivity

Instrument• Business Excellence• Productivity Gain

Measurement (PGM)

EXITASSESSMENT

PHASE 3:CONNECTIVITY

PHASE 2:CAPACITY & CAPABILITY

BUILDING

PHASE 1:MINDSET CHANGE

• Train on Trainer• Kaizen Champion• Awareness Program• Local & International Best

Practices Exposure• Team Initiator (TI) • Hands-on Workshop• Top Management Awareness

• Identify Project Process Critical Reject, Defect Customer Complaint

• Lean Process Improvement Kaizen Gemba PDCA / (Current & Future

State) 5S QCC VSM

• Yokoten• B.P Sharing• Summit• Team Excellence Convention• Creanova• COP/ Associates• Publicatons (Just Lean)• Case Study

CULTURE DEVELOPMENT AND SUSTAINABILITY

• Mindset Change• KAIZEN Concept (Muda, Mura, Muri)

Project Deployment

HEALTH CHECK

Policy Review

Recognition (Productivity Champion &

Certificaion)

Team Excellence / CreaNova(Project Based Award /

Sharing)

Asia Summit

Award APIC TE

IETEX / ASQ Convention

Post Assessment

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MPC Systems Development

Programme

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Assessment in :

• Health Check

• Business

Excellence

• SCORE

• Productivity

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• Gemba

• Value Stream

Mapping/7 QC

Tools/Kaizen/TQM

• Consulting Project

& Improvement

• Post Project

Assessment

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• Sharing sessions:

Hands-on

Workshop (HoW)

Study Mission

Team Excellence

Convention

Publications

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Certificate of

Recognition:

• Organisation

Recognition – 5S ,

Lean Recognition

• Individual through

Productivity

Champion

ASSESSME

NT

SYSTEMS

DEVELOPME

NT

BEST

PRACTICES

RECOGNITI

ON

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KAIZEN Outreach

Programmes

1. SYSTEMS DEVELOPMENT2013 2014 2015 2016 TOTAL

NO. OF PARTICIPANT 3,787 8,480 4,368 6,707 22,342

NO. OF ORGANISATION 34 158 113 129 434

2. STUDY MISSION2013 2014 2015 2016 TOTAL

NO. OF PARTICIPANT 107 25 43 56 231

NO. OF ORGANISATION 82 20 37 48 187

Launched 19 November 2014, completed 15 FMM members participated 100% HRDF claimable

No Scope Impact

1.Increase in Overall Equipment

Efficiency(OEE)> 20%

2. Reduction in Work-in-Progress >60%

3. Reduction in Downtime 20-50%

4. Increase in Production Output 37%

5. Reduction in Manpower 20-50%

“With the adoption of LEANsystem in our factory,productivity has increasedby 62%. This will immenselyhelp meet future marketchallenges” - VSP

“We are very pleased to participate in this pilot project. Our output hasincreased by 30% just 3 months after the project was implemented. I stronglyencourage companies to participate in this programme”. - Elite 13

Impact From Projects (MPC-

FMM)

KAIZEN IMPACT (PROJECT COLLABORATION MPC –SME CORP)

SALES TURNOVER

COST SAVING

PROCEESEFFICIENCY

LINE BALANCING WORKER OPTIMIZATION

RM2.83 M

RM19.7 M55 (2%)employee

Total employee = 2768 PROCESS ELEMINATION

KERJA 207(20%) WORK PROCESS BEEN

ELEMINATED FROM 1012 WORK PROCESS

69SME

ORGANIZATION

(6 SME)

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20 %

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Moving Forward : Areas for

Collaboration

Recognition through :

Best Practices Sharing by CEOs of successful

SMEs to inspire others Graduation Day for

excellent SMEs and Personnel.

Ensuring Sustainability of KAIZEN Programmes

Productivity & Innovation

Culture Pledge

• Arrangement with CEOs

of SME to commit to this

pledge.

Linking application of

loans/assistance to

productivity pledge and

improvement projects

with tangible impact.

Systems Development Through Training of

Trainers Project Implemented Core personnel in

companies identified, trained and recognized

once project completed

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Malaysia Productivity Corporation (MPC)Lorong Produktiviti , 46200 Petaling Jaya,

Selangor, MalaysiaTel : 03-79557266 Fax : 03-79578068

Email : rosmi@mpc.gov.my