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Optimizing operation performance is every Entrepreneur’s Idealistic Vision to maximize return on investment. It lays down stringent, yet achievable levels of operations, whereby an organization strives to achieve the highest possible productivity and total quality effectively, but at the lowest cost possible. Thus enhancing Quality & Productivity performance calls for organizations to take steps on a regular basis to reduce its costs through the elimination or reduction of wastes. To achieve this, firstly, all employees should be trained on quality and productivity improvements programs - - programs that change the mindset and encourage the workers to continuously improve themselves, to take simple, systematic and successful steps to improve their own workplace.  An improved and organized workplace is also a safer & more productive place. It will leads to a better working environment for all and happy workers.  The improvement ideas taught in these programs such as GEMBA KAIZEN, 5S, Visual Management, POKA-YOKE, as well as working as a team are proven techniques practiced by all world-class manufacturing and services industries worldwide.



At the end of the course, participants will be able to:

  • Describe what it takes and how to improve Quality & Productivity at the workplace
  • Recognize management approaches that satisfy customers through:
    - cost competitiveness
    - high quality products/services
    - speed of delivery, and innovation.
  • Describe what is GEMBA KAIZEN and how to continuously improvement one’s workplace
  • Implement simple and practical 5S+1S Housekeeping Principles to improve productivity and safety.
  • Use and practice simple Visual Management techniques at the workplace
  • Describe how we can achieve Zero Defects Quality through POKA-YOKE practices
  • Exercise teamwork and experience working as a team


In order to maximize the participants' learning and retention, this course uses the following methods:
  • Lecture, Group & Paired-Discussions.
  • Case studies
  • Exercises and action plans
  • Quizzes
course contents:


  • What is Quality?
  • What is Productivity?
  • Benefits of quality & productivity enhancements.
  • Workers’ responsibilities towards quality & productivity improvements.
  • Japanese factories – well known for its quality& productivity excellence. How and why?

Wastes (MUDA), Productivity, Quality

  • What is waste? How reduction of wastes can improve productivity & quality?
  • Seven types of wastes (TIMWOOD)
  • Simple KANBAN system to track inventory
  • Practical 5S + 1S practices and the elimination of wastes
  • Video: 5S Good Housekeeping Principles

GEMBA KAIZEN: Making Continuous Improvements

  • What is GEMBA KAIZEN?
  • Why & how can we implement improvements continuously?
  • Practical GEMBA KAIZEN: Visual Management practices in manufacturing

POKA YOKE: Zero Defects

  • What is POKA-YOKE?
  • Strategies for Zero Defects?
  • 10 types of human mistakes
  • Exercises: Designing practical POKA-YOKE system
  • Principles for POKA-YOKE improvements
  • Making suggestions for POKA-YOKE.

Work Planning & Controlling

  • Simple & practical basic production planning methods
  • Why plan?
  • How to control production achievements
  • Exercise: Practical production scheduling and actions plan.
who should attend:
  • Managers, Executives, Supervisors, Technicians, Group Leaders and other employees selected for plant wide productivity and quality improvement initiatives
administrative details :
Duration : 2 days
Time : 9.00am - 5.00pm
Venue : In-house or public program
Language medium : English
Trainer :
Nelson Kok (please click here to see trainer's profile)

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