IE With Lean Concepts For Non-IE Background


Industrial engineering (IE) is a branch of engineering which deals with the optimization of complex processes, systems or organizations. Industrial engineers work to eliminate waste of time, money, materials, man-hours, machine time, energy and other resources which consider as non-value added. As industrial organizations profit from technological developments, the size and the complexity of manufacturing units increased dramatically.

IE is widely known as a blend between engineering and management. IE involves many principles of management but only scientific management. In addition to management, industrial engineering is also studying other social sciences such as cognitive psychology. IE often use manufacturing industry as a model but is not only for manufacturing industry.

This knowledge can be applied across all types of industries ranging from mining industry, oil & gas industry, transportation industry, service industry and so on. IE can also be applied in any system whether it is industrial or not. Therefore, this field is also often referred to as systemic engineering. 

Industrial Engineers work to make things better, be they processes, products or systems including on how to achieve LEAN manufacturing status. LEAN means creating more value for customers with fewer resources. A LEAN organization understands customer value & focuses its key processes to continuously increase it. The ultimate goal is to provide perfect value to the customer through a perfect value creation process that has zero waste.


  • Module 1: Overview
    • What is Industrial Engineering (IE)?
    • Why IE is important?
    • Key Elements of IE
    • How to implement IE?
    • What is LEAN manufacturing?
  • Module 2: Work Measurement (Time Study)
    • Normal and standard time
    • Allowances
    • Avoidable and unavoidable delays
    • Time study procedure
    • Performance rating systems
  • Module 3: Ergonomics
    • Ergonomics
    • Motion Economy
    • Workplace design
  • Module 4: Line balancing
    • Line Balancing Rules
    • Learning and Fatigue
    • Line Balancing Procedure
    • Line Shutdown Alternatives
  • Module 5: TAKT Time
    • TAKT time vs Cycle time
    • TAKT time calculation
  • Module 6: Heijunka (Demand Leveling)
    • Definition
    • Why its important concept?
    • What are the key components?
  • Module 7: Capacity calculation
    • What is capacity planning ?
    • What is short and long term capacity plan?
    • What is constraint & unconstraint capacity?
  • Module 8: Manufacturing Lead Time
    • What is lead time means?
    • Lead time calculation and key assumptions
    • What the differences between design and actual lead time
  • Module 9: Flow
    • Spaghetti diagram
    • Push vs Pull system
    • Kanban
  • Module 10: Factory layout
    • Key principles
    • Work flow
    • What is process layout?
    • What is product layout?
    • What is group technology (Cellular) layout?
  • Module 11: Factory layout simulation
    • What is factory layout simulation?
    • Common examples of factory layout simulation
    • Key principles of simulation design
    • Check and balance (actual versus plan of record).
  • Module 12: Value stream mapping
    • Definition
    • Why its important concept?
    • What are the key components?
  • Module 13: Bottleneck analysis
    • Definition
    • Why its important concept?
    • What are the key components?
  • Module 14: Action plan
    • PDCA



This course is designed for technical and non-technical executive group with no background in Industrial Engineering, and those who are responsible for manufacturing line optimization, productivity improvement and waste reduction.



Hands-on experience and work exposure in manufacturing process, equipment, and supply chain integration for both operation and system.

Fresh graduates are also encouraged to attend this course.



  • Delivery approach:
    • Lecture using slides and multimedia
    • Group discussion
    • Sample of industry best practices
    • Assessment test
    • U shape class set up



Mr. Azhar has over 23 years of experience and accomplishments in a Senior Management capacity in the Multinational Corporation (MNC) primarily accountable for Global Supply Chain Management, New Product/Process Development, Plant Management, Virtual Factory Management, Workforce/Industrial Transformation program and talent development program. Mr Azhar has managed and lead cross functional organization such as R&D, NPI and Supply Chain group across the globe on new product development and transfer in many countries within Asia, Europe and USA.

Mr Azhar graduated from Bradley University, Peoria Illinois USA (1994) in Engineering and since then has served various sectors including heavy industries, Disk Drive Storage, Semiconductors products in Wireless Communication, Motion controller, Optoelectronics and Photomask engineering.

Mr Azhar has also held different management roles including Equipment Manager, Engineering Manager, New Product Introduction and Development Manager, Supply Chain Manager, General Manager and Managing Director before he left the industry and fully focusing on providing training and consultancy services.

Mr Azhar has spent substantial amount of time in providing training on technical problem solving tools, change management and personal self-development such as Critical Thinking, Total Productive Maintenance (TPM) pillars, Problem Solving Tools such as 8D, PDCA, DMAIC, Lean Manufacturing Concepts and waste management and the latest on the introduction to Industry 4.0 nine technology pillars concepts and principles.



2 days (9:00 am – 5:00 pm)



15 – 16 August 2017



Program 100% Claimable under SBL Scheme

PSDC Members:        RM 900/pax

Non-Members:            RM 950/pax