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Kaizen Champion Development Program

Embedded continuous improvement for manufacturing excellence

A comprehensive five-day program designed for engineers, operations managers, and team leaders who drive sustainable operational improvement. Learn proven methodologies from over two decades of industry deployment across Fortune 500 manufacturers.

Reserve Your Spot View Curriculum
5
Intensive Days
90
Days Coaching
10x
Average ROI
15
Max Cohort Size

Why Kaizen?

Kaizen—continuous improvement embedded in daily operations—is the difference between reactive firefighting and systematic, sustained improvement. Organizations that embed this methodology see measurable results within weeks.

Investment Returns: Typical kaizen projects eliminate RM 50,000–80,000 in annual waste (scrap, downtime, rework, inventory, labor). ROI ranges from 10x within 6 months. Most organizations recover the program investment from their first improvement initiative.

This is not theoretical training. 80% of the curriculum is applied directly to your operations, using your data, solving your challenges.

Root Cause Analysis

5 Why, Fishbone, and 7QC Tools applied to your actual operational data.

A3 Report Methodology

Communicate improvement logic on one professional page—standard across leading manufacturers.

90-Day Implementation

Structured coaching to ensure improvements lock in and prevent regression.

Online Coaching Sessions

6 bi-weekly sessions over 3 months. Email support and consultations throughout.

Program Objectives

Participants will develop the knowledge, skills, and mindset to lead sustainable operational improvement in their organizations.

Kaizen Philosophy & Leadership

Understand the history, principles, and role of a Champion in embedding continuous improvement culture.

Waste Identification

Recognize and quantify the 8 Wastes in your operations—overproduction to underutilized talent.

Baseline Assessment

Establish current state using Quality, Cost, and Delivery (QCD) framework—the business language of improvement.

Root Cause Analysis

Apply 5 Why, Fishbone diagrams, and systematic thinking to find true causes, not symptoms.

Data-Driven Problem Solving

Master 7QC Tools: Check Sheets, Pareto, Histograms, Control Charts. Make decisions on data, not opinion.

Countermeasure Design

Create effective solutions using Poka Yoke, Jidoka, Visual Management, and Standard Work.

A3 Reporting

Develop professional one-page improvement reports. Communicate logic, data, and action plans clearly.

Implementation Leadership

Plan and execute kaizen initiatives with clear ownership, KPIs, pilot strategies, and daily accountability.

Culture & Sustainability

Lock in gains, prevent regression, build internal capability, develop future champions through mentorship.

KPI Management

Design dashboards, quantify business impact, communicate improvement ROI to leadership.

Team Development

Coach team members through PDCA cycles, build problem-solving capability, scale continuous improvement.

Change Leadership

Lead teams through transformation. Manage resistance, build buy-in, sustain momentum.

Learning Outcomes

Knowledge Competencies

  • Kaizen philosophy and competitive advantage
  • The 8 Wastes (Muda) framework
  • QCD business impact model
  • PDCA continuous improvement cycle
  • Root cause analysis methodologies
  • 7 Quality Control Tools
  • Poka Yoke and Jidoka concepts
  • A3 Report structure and logic

Technical Skills

  • Baseline assessment and data collection
  • Perform systematic root cause analysis
  • Apply 7QC Tools for data analysis
  • Design countermeasures and controls
  • Facilitate 5S audits and assessments
  • Document standard work procedures
  • Create professional A3 Reports
  • Plan and pilot improvements
  • Lead daily management reviews
  • Develop KPI dashboards
  • Coach team members through PDCA
  • Manage implementation and change

Leadership Mindset

  • Waste exists in every process
  • Reality is on the factory floor
  • Data drives every decision
  • Root causes are systemic, not personal
  • Small improvements compound exponentially
  • Culture sustains results long-term
  • Frontline staff are your best experts
  • Lead by coaching, not controlling
  • Address resistance with empathy

5-Day Curriculum

May 18–22, 2026 | 9:00 AM – 5:00 PM | De Palma, Shah Alam

Limited to 15 participants per cohort

Day 1Foundation of Kaizen ∧

Learning Focus: Kaizen philosophy, Champion leadership role, QCD framework, PDCA methodology, operational excellence mindset

MORNING: 9:00 AM – 1:00 PM
  • Program Overview & Participant Introductions — Setting context and building group cohesion
  • Kaizen: Philosophy & Historical Context — Origins, evolution, and relevance to modern operations
  • The Role of a Kaizen Champion — Responsibilities, required competencies, organizational impact
  • QCD Framework — Quality, Cost, Delivery and their interconnection to profitability
  • The PDCA Cycle — Plan-Do-Check-Act as the engine of continuous improvement
AFTERNOON: 2:00 PM – 5:00 PM
  • Reactive vs. Proactive Mindset — From crisis management to prevention
  • Champion Competencies Framework — Technical, leadership, and change management skills
  • Operational Excellence Case Study — Analysis of successful improvement methodologies
  • PDCA Exercise: Applied Problem Solving — Small group practice on operational challenges
  • Personal Goal Setting — Individual commitment to learning and action
Day 2Baseline & Problem Identification ∧

Learning Focus: Current-state assessment, 8 Wastes, assessment methodology, data collection, 5S framework

MORNING: 9:00 AM – 1:00 PM
  • Day 1 Recap & Reflection — Reinforcing PDCA and QCD concepts
  • The 8 Wastes (Muda) — Overproduction, Waiting, Transport, Processing, Inventory, Motion, Defects, Talent
  • Baseline Metrics & KPIs — Cycle time, defect rate, downtime, lead time, labor productivity
  • Assessment Methodology — Systematic approach to understanding current state
AFTERNOON: 2:00 PM – 5:00 PM
  • Process Assessment — Structured observation and data collection methods
  • Waste Identification Workshop — Recognize each type of waste in your process
  • 5S Framework — Sort, Set, Shine, Standardize, Sustain: organizing for efficiency
  • Data Collection Planning — Define process, select metrics, assign ownership, establish timeline
Day 3Root Cause Analysis & Solutions ∧

Learning Focus: Systematic root cause analysis, data-driven problem solving, countermeasure design, implementation planning

MORNING: 9:00 AM – 1:00 PM
  • Root Cause Analysis Overview — Why symptoms must lead to systemic causes
  • 5 Why Analysis Method — Drilling down to true root causes through structured questioning
  • Fishbone Diagram Construction — Man, Machine, Method, Material, Environment framework
  • 7 Quality Control Tools — Check Sheet, Pareto, Histogram, Run Chart, Scatter Plot, Stratification, Control Chart
AFTERNOON: 2:00 PM – 5:00 PM
  • Data Analysis Workshop — Apply 7QC Tools to your baseline data, identify patterns
  • Countermeasure Development — Design specific, testable solutions to root causes
  • Quality Control Circles (QCC) — Employee-led problem-solving and suggestion systems
  • Implementation Plan Framework — Who, what, when, resources, success metrics
Day 4Implementation & Leadership ∧

Learning Focus: A3 reporting, mistake-proofing, visual management, standard work, change leadership

MORNING: 9:00 AM – 1:00 PM
  • Implementation Mindset — From analysis to execution; starting small with pilot approaches
  • A3 Report Development — One-page improvement communication: background, analysis, solutions, plan, results
  • Poka Yoke (Mistake-Proofing) — Design processes to prevent errors before they occur
  • Jidoka (Autonomation) — Build in quality; processes/machines stop when abnormality detected
AFTERNOON: 2:00 PM – 5:00 PM
  • Visual Management Systems — Make status, problems, and targets visible at a glance
  • Andon System — Visual signals for abnormalities; production stops to address issues immediately
  • Standard Work Documentation — Best known method: sequence, timing, quality criteria
  • Leading Change — Communicate why, involve staff, train thoroughly, celebrate early wins
  • Pilot & Rollout Strategy — Start small, monitor daily, adjust quickly, scale to full deployment
Day 5Sustainability & Culture ∧

Learning Focus: Locking in improvements, preventing regression, building culture, KPI management, mentorship

MORNING: 9:00 AM – 1:00 PM
  • Sustainability Strategy — Improvement is easy; sustaining it is the challenge
  • Systems & Habits for Sustainability — Standard work audits, visual metrics, accountability, recognition
  • Preventing Regression — Monthly reviews, quick-fix protocols, training refreshes, next-phase planning
  • Motivation & Engagement — Clear purpose, early wins, autonomy, growth opportunities
  • Managing Resistance — Address fear, habit, effort, ownership barriers with empathy and communication
AFTERNOON: 2:00 PM – 5:00 PM
  • KPI Tracking & Dashboards — Quality, Cost, Delivery metrics over 90+ days
  • Business Impact Calculation — RM savings, ROI, payback period, link to business strategy
  • Mentorship & Coaching Framework — Identify potential, coach through PDCA, develop next leaders
  • Capstone Presentations — Each participant presents A3 Report, peer feedback, celebration
  • 90-Day Action Plan Review — Coaching schedule, email support, alumni network, next steps
  • Closing Ceremony — Recap, commitment, thank you, networking

Program Includes

Complete Tools Handbook

A3 templates, Fishbone diagrams, Check Sheets, Pareto charts, 5S assessments, Standard Work forms, Visual Management templates.

Data Analysis Workshop

Apply 7QC Tools to your baseline data. Analyze patterns. Develop countermeasures specific to your operation.

A3 Report Guidance

Template, worked example, peer review during program. Leave with a complete, ready-to-present improvement plan.

90-Day Coaching

6 bi-weekly online sessions over 3 months, email support, phone consultations. Lock in improvements and prevent regression.

Process Assessment

Structured evaluation of your current operations using QCD framework. Identify improvement opportunities.

Implementation Roadmap

Clear 90-day execution plan with milestones, ownership, KPI targets, and success metrics.

Pricing

Early Bird

Register by April 30

RM 4,500
  • 5-day intensive program
  • All tools & templates
  • 90-day coaching (6 sessions)
  • Complete A3 Report
  • 90-day Implementation Roadmap
Register

Standard

Regular rate

RM 5,000
  • 5-day intensive program
  • All tools & templates
  • 90-day coaching (6 sessions)
  • Complete A3 Report
  • 90-day Implementation Roadmap
Reserve Now

Group Rate

3 or more participants

RM 4,500
  • 5-day intensive program
  • All tools & templates
  • 90-day coaching (6 sessions)
  • Complete A3 Report
  • 90-day Implementation Roadmap
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Investment Returns

Typical kaizen projects eliminate RM 50,000–80,000 in annual waste (scrap, downtime, rework, inventory, labor). Average ROI: 10x within 6 months. Most organizations recover the program investment from their first improvement initiative.

Frequently Asked Questions

Do I need Lean or manufacturing experience? ∧
No. This program is self-contained and designed for operations professionals at any experience level. If you've done Lean before, this deepens that knowledge. If you haven't, this is a complete introduction. We assume only that you understand your process.
We tried improvements before. Nothing lasted. Why would this be different? ∧
Most improvements fail during the 6 months after training—not because the solution is flawed, but because follow-up is missing. This program includes 90 days of structured coaching to ensure improvements lock in. You get a sustainability plan on Day 5 and support throughout implementation.
Is this customized to our industry? ∧
Yes. 80% of the program is applied directly to YOUR process, YOUR challenges, and YOUR data. Whether you're automotive, electronics, food, pharma, or process manufacturing, we adapt examples and case studies. The assessment is on your operations.
What happens after the 5 days? ∧
You receive 90 days of structured support: 6 bi-weekly online coaching sessions (1 hour each), 24-hour email response, phone consultations as needed, and alumni network access. We track implementation milestones, refine your KPI dashboard, and help scale improvements across your operation.
How do we measure ROI? ∧
We track QCD metrics: defect rate, scrap %, cost per unit, lead time, on-time delivery %. You create a KPI dashboard on Day 5 with baseline, targets, and RM impact. Most companies see measurable savings within 90 days. Average ROI: 10x.
Who should attend? ∧
Manufacturing supervisors, engineers, operations managers, plant leaders, quality managers. Anyone responsible for process improvement or who directly manages teams on the floor. Mixed cohorts (different industries, functions) are ideal—peer learning is powerful. We limit to 15 participants for hands-on engagement.
Can you run this at our facility? ∧
Yes, for larger groups (8+). In-house delivery at your facility. Contact us to discuss dates, location, and customization options.

Reserve Your Spot

May 18–22, 2026 | 9:00 AM – 5:00 PM | De Palma, Shah Alam

Limited to 15 participants per cohort

Questions?
Husni Halim | Principal Consultant
+60 16-526-1901 | husnihalim@visiarmada.com
visiarmada.com