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https://mechanical.eng.usm.my/index.php/ms/

USM Lean Six Sigma, School of Mechanical Engineering USM, Nibong Tebal (2026)

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School Of Mechanical Engineering USM

02/10/2026

Meet our Lean Six Sigma Yellow Belt trainers!

Introducing Ir. Dr. Nur Amalina Binti Muhammad and Dr. Hasnida Binti Ab Samat, Senior Lecturers from the School of Mechanical Engineering, Universiti Sains Malaysia (USM).

With expertise in Lean Six Sigma, manufacturing systems, production management and continuous improvement, both trainers bring teaching, research and industry engagement experience to the programme.

Through interactive discussions and hands-on activities, they will guide participants in identifying waste, understanding root causes and applying practical tools to improve processes. Expect a learning experience that connects Lean Six Sigma concepts with everyday workplace challenges!

Let’s learn, collaborate and build a continuous improvement mindset together. 💪

27/08/2026

🌏 LEAN@USM GOES INTERNATIONAL! 🇲🇾🤝🇮🇩

From Penang to Medan — Lean@USM's international journey just took another step forward.

We're proud to share our latest collaboration with PT Victorindo Pratama Mandiri (Victorindo Group) in Medan, Indonesia, where we ran a full Lean Six Sigma Yellow Belt Training programme for 24 Victorindo staff. The 10-module programme started online via Lark in June and July 2026, then moved to face-to-face sessions on 20 to 22 August at the Victorindo Group Learning Institute in Medan, delivered together with the Department of Industrial Engineering at Universitas Sumatera Utara (USU).

Over the course of the programme, participants worked through the full spectrum of Lean thinking — from leadership and culture down to the statistical tools that make improvement measurable. They looked at Lean management and principles, change management, employee engagement, and what it actually takes to build a Lean culture. They got hands-on with visual management and 5S, waste elimination, PDCA, and root cause analysis using tools like the 5 Whys, fishbone diagrams, prioritisation matrices and process mapping. On the more technical side, they picked up statistical process control — run charts, histograms, scatter diagrams and control charts — supported by software-based SPC learning. None of it stayed theoretical: case studies, group activities, LEGOPlane and HoM simulations kept everything tied back to real production floor problems.

The programme closed with an online test and graduation, sending 24 newly minted Lean Six Sigma Yellow Belters back to their workplaces. 🎓👏

One moment from the closing ceremony stayed with us. Mr. Kunaefi Siswady, Managing Director of Victorindo Group, told us: "Trima kasih banyak atas training nya yg sangat luar biasa 🙏" Thank you, Mr. Kunaefi and the whole Victorindo team, for the trust and the energy you brought to this partnership. ❤️

This marked the second time Lean@USM has taken its training abroad. The first was back in January 2024, a Lean Six Sigma White Belt programme delivered at Bangkok Hospital Hat Yai in Thailand, in partnership with Prince of Songkla University. From healthcare in Thailand to manufacturing in Indonesia, the thread running through both is the same — continuous improvement doesn't stay in one industry or one country once it takes hold.

Learn Lean. Practise Lean. Improve together. From USM to the world. 🌏✨
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🌏 LEAN@USM MELANGKAH KE PERINGKAT ANTARABANGSA! 🇲🇾🤝🇮🇩

Dari Pulau Pinang ke Medan — perjalanan antarabangsa Lean@USM terus berkembang.

Kami dengan bangga berkongsi kerjasama antarabangsa terbaharu bersama PT Victorindo Pratama Mandiri (Victorindo Group) di Medan, Indonesia, di mana kami telah menganjurkan program Latihan Lean Six Sigma Yellow Belt sepenuhnya untuk 24 orang kakitangan Victorindo. Program 10 modul ini bermula secara dalam talian menerusi aplikasi Lark pada Jun hingga Julai 2026, sebelum diteruskan dengan sesi bersemuka pada 20 hingga 22 Ogos di Victorindo Group Learning Institute, Medan, hasil kerjasama dengan Jabatan Kejuruteraan Perindustrian, Fakulti Kejuruteraan, Universitas Sumatera Utara (USU).

Sepanjang program ini, para peserta didedahkan kepada skop Lean yang menyeluruh — bermula daripada kepimpinan dan budaya organisasi, sehinggalah kepada alat statistik yang membolehkan penambahbaikan diukur dengan jelas. Mereka mempelajari pengurusan dan prinsip Lean, pengurusan perubahan, penglibatan pekerja, serta cara membina budaya Lean yang mampan. Peserta turut didedahkan kepada pengurusan visual dan 5S, pengurangan pembaziran, PDCA, serta analisis punca masalah menggunakan teknik seperti 5 Why, gambar rajah tulang ikan (fishbone), matriks keutamaan dan pemetaan proses. Dari segi teknikal p**a, mereka mempelajari kawalan proses secara statistik — carta larian, histogram, gambar rajah serakan dan carta kawalan — disokong dengan pembelajaran SPC berasaskan perisian. Semua ini tidak tinggal sebagai teori semata-mata; kajian kes, aktiviti berkump**an, simulasi LEGOPlane dan HoM memastikan pembelajaran sentiasa dikaitkan dengan masalah sebenar di lantai pengeluaran.

Program ini berakhir dengan ujian secara atas talian dan majlis graduasi, melahirkan 24 peserta yang kini bergelar Lean Six Sigma Yellow Belt. 🎓👏

Satu detik yang amat bermakna dalam majlis penutup ialah ucapan daripada Encik Kunaefi Siswady, Pengarah Urusan Victorindo Group: "Trima kasih banyak atas training nya yg sangat luar biasa 🙏" Terima kasih Encik Kunaefi dan seluruh warga Victorindo atas kepercayaan dan semangat yang diberikan sepanjang kerjasama ini. ❤️

Ini merupakan kali kedua Lean@USM membawa latihannya ke luar negara. Kerjasama antarabangsa pertama telah dijalankan pada Januari 2024, iaitu program Lean Six Sigma White Belt di Bangkok Hospital Hat Yai, Thailand, dengan kerjasama Prince of Songkla University. Daripada sektor kesihatan di Thailand kepada sektor pembuatan di Indonesia, satu perkara yang jelas — semangat penambahbaikan berterusan tidak terhad kepada satu industri atau satu negara sahaja apabila ia benar-benar tertanam.

Belajar Lean. Amalkan Lean. Berkembang bersama. Dari USM ke seluruh dunia. 🌏✨

23/06/2026

Lean Six Sigma Yellow Belt Wave 13
Class #10 Summary
Topic: Basic Statistics and Lean Management Systems 2
Date: 22 April 2026 | Time: 6:00 – 10:00 PM
Location: MEK 3, School of Mechanical Engineering
Instructors: Ir. Dr. Nur Amalina Muhammad.

This session focused on reinforcing fundamental concepts of basic statistics and their application in Lean Management Systems. Students reviewed key statistical tools used for data analysis and decision-making in process improvement.

The session also introduced the PDCA (Plan-Do-Check-Act) template, highlighting its role as a structured problem-solving and continuous improvement method widely used in Lean practices. Emphasis was placed on how each stage of PDCA supports systematic evaluation and refinement of processes.

In addition, the class continued with a summary of the HELP Simulation (Round 2 and Round 3). During this activity, students estimated the average time taken for the simulation, and the student with the closest estimate was rewarded with a prize, making the learning experience more interactive and engaging.

A Jeopardy-style activity was also conducted to further enhance engagement and reinforce understanding through an interactive review format. The session concluded with discussions on key Lean topics, including customer focus, leadership, Lean foundation, process improvement, and creating a Lean culture.

Overall, the session aimed to strengthen understanding, encourage active participation, and prepare students to apply Lean principles and continuous improvement techniques in practical situations.

Prepared by: Teoh Wei Jun, Yep Hui Wen

18/06/2026

🎓 Congratulations to All Participants of the PDCA Project Presentation! 🎓

On 17 June 2026, we proudly witnessed the successful completion and presentation of 8 PDCA (Plan-Do-Check-Act) improvement projects by participants at Nefab (M) Sdn Bhd.

Throughout the programme, each group demonstrated remarkable commitment, teamwork, problem-solving skills, and continuous improvement practices. Their presentations showcased innovative solutions, measurable improvements, and the effective application of the PDCA methodology to address workplace challenges.

A special congratulations to all 20 participants for successfully completing their projects and presenting their achievements with confidence and professionalism. Your dedication to continuous improvement reflects the true spirit of operational excellence.

The event also marked a significant milestone as participants proceeded to their graduation ceremony, celebrating not only the completion of the programme but also their growth in knowledge, skills, and leadership capabilities.

Thank you to the management team, facilitators, mentors, and all participants for making this programme a success.

👏 Well done and congratulations to all graduates! May this achievement inspire continued excellence and continuous improvement in the workplace.

17/06/2026

🎉 Empowering Leaders Through Lean Thinking! 🎉

On 10 June, we had the privilege of conducting a Lean Management Training for the Directors and Managers of B. Braun Medical Industries, Bayan Lepas Penang.

The session was filled with engaging discussions and, most importantly, an exciting hands-on LEGO simulation activity that brought Lean concepts to life. Participants experienced firsthand how Lean tools and principles can be applied to improve processes, eliminate waste, enhance teamwork, and create greater value for customers.

🧩 Learning by doing made the session both fun and impactful, allowing participants to translate theory into practice through interactive challenges and continuous improvement exercises.

Key Lean concepts and tools explored included:
✅ Waste Identification
✅ Continuous Flow
✅ Pull System
✅ Standardization
✅ Team Collaboration
✅ Continuous Improvement Mindset

A big thank you to the leadership team from B. Braun Penang for their active participation, enthusiasm, and commitment to operational excellence.

Together, we continue building a culture of continuous improvement and sustainable excellence. 🚀

23/04/2026

🌟𝐄𝐱𝐜𝐢𝐭𝐢𝐧𝐠 𝐋𝐞𝐚𝐧 𝐒𝐢𝐱 𝐒𝐢𝐠𝐦𝐚 𝐘𝐞𝐥𝐥𝐨𝐰 𝐁𝐞𝐥𝐭 𝐓𝐫𝐚𝐢𝐧𝐢𝐧𝐠 𝐉𝐨𝐮𝐫𝐧𝐞𝐲 | 𝐈𝐧𝐝𝐮𝐬𝐭𝐫𝐲 𝐖𝐚𝐯𝐞 𝟒 – 𝟐𝟎𝟐𝟔 🌟

Hello everyone!

📚 We have just completed an incredible 10-day Lean Six Sigma Yellow Belt Certification training journey, successfully covering 10 engaging modules together. We are truly delighted to have shared this meaningful experience with such a fantastic group of participants.

🚀 Heartiest congratulations to the 20 participants from Nefab (Malaysia) Sdn. Bhd. for their commitment, dedication, teamwork, and outstanding performance throughout the training. Your enthusiasm and positive spirit made this journey truly impactful and unforgettable.

🦸‍♂️ We are also pleased to see the participants continuing their improvement efforts through PDCA projects in addressing actual problems within the company. This shows their readiness to apply the Lean Six Sigma knowledge gained during the training into practical workplace solutions while strengthening a culture of continuous improvement within the organization.

💪 To our amazing Lean team, let us continue to uphold the Lean Six Sigma spirit and keep turning challenges into opportunities. This is only the beginning of a meaningful journey towards continuous improvement.

🌐 For any inquiries regarding Lean Six Sigma training, feel free to contact us via inbox or email: [email protected]

The 20 outstanding participants of the Lean Six Sigma Yellow Belt Certification - Industry Wave 4 are:
* ANIS FALAHIAH BINTI SEBERI
* CHEANG MEI THENG
* CHEANG MEI WAN
* CHIA DI-SHENG
* CHIN JIAN YEAN
* CHONG MEI YONG
* CHUAH SHANG JEE
* DHILIP KUMAR VENKATESAN
* LAU KHA WAI
* LIM SIEW PING
* LOO PEI XUAN
* MOHAMAD ZUBIR BIN ZAINAL ABIDIN
* MUHAMMAD HAFIZUL FAIZ BIN TAJUDDIN
* MUHAMMAD IMRAN BIN ASMADI
* NG PEI HOON
* NUR LIYANA BINTI SAIDI
* OLIVIA ONG BEE LU
* OOI EE CHIA
* TAN MAN WEI
* TAN SHEUE JIUN

22/04/2026

Lean Six Sigma Yellow Belt – Wave 13
Class Summary #9: Basic Statistics and Lean Management System 1
Date:20 April 2026 (Monday)
Time: 6:00 PM – 10:00 PM
Venue: MEK 3, School of Mechanical Engineering
Main Instructor: Ms. Beh En Qi (Alumni, Lean Wave 12) & Dr. Hasnida

The session began with Ms. Beh En Qi introducing fundamental concepts of basic statistics. The focus was placed on graphical representations of the mean and standard deviation, as well as the application of the 68–95–99.7 rule. As a practical exercise, the class constructed a histogram using the height data collected from students. In addition, we examined various out-of-control symptoms by analyzing and sketching seven different types of control chart patterns under varying conditions.

The class was subsequently introduced to the key elements of the Lean Management System. These elements include Leaders’ Standard Work (the engine), Daily Accountability (the gas pedal and steering wheel), Visual Controls (the transmission), and Discipline (the fuel). The concept of a tiered management structure was also explored.

Following the dinner break, the session continued with the HELP Simulation (Round 2), during which several changes were implemented to enhance the system’s performance. After that, we are given ten minutes to discuss potential improvements for the final simulation round (Round 3). In Round 3, these proposed improvements were applied, allowing us to observe the impact of systematic enhancements on overall performance.

Towards the end of the session, we were divided into groups to discuss the development of the problem statement and SMART goals for our PDCA projects with our respective instructors. This discussion provided guidance on structuring effective and measurable project objectives.

Overall, the session enhanced our understanding of basic statistics and Lean principles while preparing us to apply them in our PDCA projects.

Prepared by Teh Jia Jia, Tan Zhen Ying & Tan Yun Qi (LSS YB Wave 13)

20/04/2026

Lean Six Sigma Yellow Belt Wave 13
Class Summary #8: Analysis Tools and Standards 2
Date: 15 April 2026 (Wednesday)
Time: 2:00 PM – 6:00 PM
Venue: MEK 3, School of Mechanical Engineering
Main Instructors: Ir. Ts. Dr. Muhammad Hafiz Hassan & Mr. Tuan Amin (Alumni Lean Wave 12)

Wave 13 continues to strengthen our understanding of Lean practices! We would like to express our sincere appreciation to Ir. Dr. Hafiz Hassan and Mr. Tuan Amin for their engaging and insightful session.

One of the highlights of this class was a shooting simulation game conducted in two rounds. In the first round, teams operated based on their own approaches without any standardized method. This resulted in inconsistencies, inefficiencies, and varying performance among teams.

Following this, Ir. Dr. Hafiz introduced the importance of standardization and Standard Operating Procedures (SOP) in improving process performance. With clearer instructions
and structured workflows, we proceeded to the second round of the simulation. The improvement was evident — teams performed more consistently, efficiently, and accurately. This activity clearly demonstrated how standardization reduces variation,
improves coordination, and enhances overall productivity, which are key principles in Lean Six Sigma.

The session reinforced the importance of establishing and maintaining standards as a foundation for continuous improvement and operational excellence.

Additionally, the session included a valuable sharing by Mr. Tuan Amin, where he presented on the use of interactive data visualization using Power BI in Lean simulations. This sharing
provided us with insights on how data can be effectively analyzed and visualized to support decision-making, track performance, and further enhance continuous improvement efforts in
real-world applications.

Prepared by: Tan Wei Dian & Siew Wei Hong (LSS YB Wave 13)

20/04/2026

Lean Six Sigma Yellow Belt Wave 13
💡 Topic: Root Cause Analysis
📅 Date: 13 April 2026 (Monday)
🕰 Time: 6 – 10 PM
📍 Venue: MEK 3, School of Mechanical Engineering
👨🏻‍🏫 Main Instructor: Mr. James Tan (Alumni of LSS YB Wave 1 and currently Global Quality Manager at Flex)

Another insightful and engaging session for Wave 13!🚀

The session was led by Mr. James Tan, Global Quality Manager at Flex and a proud alumni of Lean Six Sigma Wave 1. With his global role, he regularly collaborates with international teams and oversees quality standards across different countries, giving us valuable exposure to how Lean Six Sigma is applied on a global scale in real manufacturing environments.

We explored the concept of Root Cause Analysis🔍, understanding its importance in identifying the real problems rather than just surface issues. The session continued with deeper analysis techniques, followed by discussions on data collection and how accurate data plays a key role in effective problem-solving.

Next, we learned about graphical tools and analysis that help us visualize data for better decision-making. One of the key tools covered was the Pareto Chart, where we identified the most significant factors contributing to problems.

The session became more interactive with the M&M activity, where we applied Pareto analysis in a fun and practical way—proving that even simple exercises can strengthen our understanding of complex concepts.

We also reviewed the HELP Simulation results where our time improved from 63.79 seconds in Round 0 to 62.43 seconds in Round 1, showing progress through continuous improvement.

The session ended with valuable takeaways on using data effectively to drive better decisions and improve processes💡.

Thank you Mr. James Tan for sharing your knowledge and inspiring us with real industry practices.

Let’s keep pushing forward Wave 13—small improvements lead to big results! 📈🔥

Written by: Atiqah & Hafizuddin (LSS YB Wave 13)

13/04/2026

Lean Six Sigma Yellow Belt Wave 13
Class #6 Summary 📝
Topic: Lean & Problem Solving Fundamentals 2
Date: 8 April 2026 | Time: 2:00 – 6:00 PM
Location: MEK 3, School of Mechanical Engineering
Main Instructors: Mr. Luqman & Mr. Tuan Amin (Alumni Lean Wave 12)
Secondary Instructor: Ir. Dr. Nur Amalina Muhammad.

Wave 13 is gaining momentum! Class #6 began with the presentation of HELP Simulation Round 0 results by Ir. Dr. Nur Amalina Muhammad, highlighting key areas for improvement as we move forward with Lean practices.

We explored PDCA Steps 1 & 2 with Mr. Luqman, focusing on defining performance gaps and eliminating non-value-added activities. Mr. Tuan Amin then guided us in analyzing process maps to identify VA, NVABR, and NVA, while setting SMART goals to improve performance.

We then applied our learning in HELP Simulation Round 1, turning theory into action in an energetic session.

A great step forward for Wave 13—let’s keep improving! 🚀📊

Written by: Low Jia Ying, Lou Yi Xuan & Marzalia (LSS YB Wave 13)

USM Lean Six Sigma

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Monday	08:00 - 17:00
Tuesday	08:00 - 17:00
Wednesday	08:00 - 17:00
Thursday	08:00 - 17:00
Friday	08:00 - 17:00