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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

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)

13/04/2026

Lean Six Sigma Yellow Belt Wave 13
Class Summary #5: Lean and Problem Solving Fundamentals 1
Date: 6 April 2026 (Monday)
Time: 6:00 PM – 10:00 PM
Venue: School of Mechanical Engineering, USM
Main Instructor: Ms. Anis Masturina (Alumni Lean Wave 8) & Ir. Dr. Nur Amalina

The journey for Wave 13 continues! This session took us deeper into the heart of Lean methodology, focusing on how we transition from identifying problems to systematically solving them. We would like to extend our gratitude to Ms. Anis and Ir. Dr. Nur Amalina for their energetic and insightful delivery.

The class opened with a comprehensive overview of the PDCA (Plan-Do-Check-Act) cycle, providing us with a structured framework for continuous improvement. We explored essential problem-solving tools, including the Fishbone Diagram and the 5 Whys technique, to help us dig beneath the surface and identify the true root causes of operational issues.

The highlight of the evening was the high-energy HELP Simulation (Round 0). In this simulation, our class was transformed into a fast-paced organization with roles ranging from Managing Director and Engineers to Citizens and Telephone Line operators. With the Director’s call for "Help in seconds!", we experienced firsthand the chaos of an unoptimized process and the critical need for clear communication and standardized workflows.

Following the simulation, we shifted our focus to the fundamentals of 5S and Visual Management (VM). We learned how a workspace that is Sorted, Set in order, Shined, Standardized, and Sustained serves as the foundation for Lean efficiency. The session concluded with a deep-dive discussion on our HELP Round 0 performance, where teams proposed "3 key changes" to improve the system for the next round.

We are excited to apply these problem-solving fundamentals as we move forward in our Yellow Belt certification!

Prepared by Kang Zhen Lin, Kee Meng Een & Lean Elaine (LSS YB Wave 13)

06/04/2026

Lean Six Sigma Yellow Belt Wave 13
Class Summary #4: Aligning the Organization 2

Date: 1 April 2026 (Wednesday)
Time: 2:00 PM – 6:00 PM
Venue: MEK3, School of Mechanical Engineering
Main Instructor: Dr. Hasnida & Mr. Syuaib (Alumni Lean Wave 12)

This session marked another important milestone in our Lean Six Sigma journey. On behalf of Yellow Belt Wave 13, we would like to express our sincere appreciation to our instructors for their valuable insights and continuous guidance.

The session began with Dr. Hasnida introducing the importance of understanding customer needs and enhancing process efficiency. Emphasis was placed on capturing the Voice of the Customer (VOC) and analyzing customer experiences to ensure that products and services meet expectations effectively.

In the following segment, we explored the concept of Cost of Poor Quality (COPQ) and its impact on operational performance. The discussion highlighted the need to eliminate non-value-added activities within processes. Tools such as the House of Quality (HOQ) were introduced to help translate customer requirements into technical specifications. Additionally, system analysis models including IPO (Input-Process-Output) and SIPOC (Supplier-Input-Process-Output-Customer) were discussed, providing structured approaches to problem-solving and improving process clarity.

After the break, the focus shifted to project selection and scoping, which is a critical part of the Plan phase in the PDCA cycle. Mr. Syuaib guided us through the initial steps and key considerations required to identify suitable projects. We were also introduced to the project prioritization matrix, where criteria are defined, projects are listed, scores are assigned, and results are analyzed to support effective decision-making.

The session concluded with a Q&A and key takeaways segment, reinforcing the concepts learned and ensuring a clear understanding of how to apply them in real-world projects.

Prepared by Izzah Awatif & Kam Shin Yen (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