Total digital transformation to Industrial 4.0 and company wide cultural Transformation to become the most preferred low cost technological manufacturing site with an edge over the competition.

1. Page 1 of 9

2. Highlights of a Successful Manufacturing Company
Innovative Products Innovative Manufacturing Strong Supply Chain Customer Base
High Profit Margin Cost Effective &
Competitive edge at
I4.0
Materials, Inventory
& Logistics
Competitive Pricing,
High Quality & Ease
Of Doing Business
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3. Productivity in the Manufacturing Plant (Digital Transformation)
A. KEY OBJECTIVES B. PEOPLE DEVELOPMENT
Low
Conversion
Cost
Grow
Customer
Base & Ease
Of Doing
Business
Alignment of
Functional
goals to
Factory goals
Empowerment
and
Engagement
Productivity
Strategy
1 2 3 2
1
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Factory Transformation to Industrial 4.0 Cultural Transformation

4. Productivity in Manufacturing Plant: Key Objective 1
Productivity Strategy
• Lean Flow Line
• TAKT Time (Test Vs Assy)
• Short Cycle Time
• Double UPH – OSA
Common losses
• Absenteeism
• Start of shift loss
• Change over loss
• Efficiency or learning loss
Maximise Output
With Lowest Cost
Efficient Utilisation Of
Manufacturing Space
Low
Conversion
Cost
1
Efficient Slim Flow Line
• Short Cycle
• Short Flow Line
• Centralize common area
• Mechanization
• Semi-automation
• Mechanical
• Test Multiplexing
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Objective :-
- Low Labour Cost
- Low Space Cost
Note :-
Conventional Productivity very Academic.

5. Illustration :- Productivity & Doubling of Output
Productivity Formula
Std Time X Vol X K
Productivity = --------------------------
Input Hours
Where :-
a. Std Time – time needed to build a product
b. Vol - Output quantity at the end of the shift
c. K - Manufacturing Allowance
d. Input Hours - Total Labor hours for the shift
Productivity Doubling UPH
(Units Per Hour)
Product Cost Structure
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Note :-
Conventional Productivity very Academic.
EEESP ( End Selling Price ) $$100
EEGP ( Gross Profit) $$20
EEFOH ( Fixed Over Head) $$25
EEBOM ( Bill of Material) $$50
EEDL ( Direct Labour) $$5
Maximize output

6. Productivity in Manufacturing Plant: Key Objective 2
Factory Engineering Capability
• 3D animated work instructions with
Virtualization.
• Magnetic Conveyor
• Automated Image recognition
• Auto laser Lead height check and trim
• Thermal Imaging Vs Conventional BI
• Automated Testing
• Dynamic Test for Significance
Scalable Capacity,
Flexibility And
Responsiveness
High Tech Manufacturing
Grow
Customer
Base with Low
cost of
operation &
Ease Of Doing
Business
2
Universal Main Line
• Universal Testing without unique
test fixture with literally no change
over loss.
• Multiple products with different
form factor can run on the line
simultaneously
• Multiplex Automated Test Equipment
• Automate mechanical assembly
wherever practical.
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Ahead of Competition
Doubling output through Lean, Productivity & Semi-automation

7. Productivity in Manufacturing Plant: Key Objective 3
Systematic Manufacturing Control
• Traceability and shop floor control
• Equipment maintenance and spare
parts control. (MMMS)
• Product process management control
(PPMS)
• Paperless transactions
Manufacturing Control
through IT Solutions
Productivity
Strategy
3 Product Quality
Waste Elimination
• Inspection
• Line yield by stations
• Mitigate scraps
• Field failure & warranty cost
Strategy
• Fix problem at Source
• Stop line for 3 consecutive failure of
the same kind.
Burn-in & Test
• Proactively screen out thermal defects
• Dynamic test for Significance
• Parametric auto CPk tracking
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8. Productivity in Manufacturing Plant: People Development 1
Alignment of
Functional
goals to
Factory goals
1
Team Work and Collaboration
• Common goals for every employee
• Embrace and engage every member
for total participation
• Core business - Battlefield
Awareness of Key Challenges
• Conversion Cost
• Customers satisfaction
• Competitiveness in the competition
• Grow customer base
Core Business Manufacturing
Create Conducive Working
Environment
Empowerment and Engagement
• Trust, Respect and Reliable
• Humble versus Pride (Ego)
• Good listener, patience & tolerance
• Eliminate Fear
• Learn from mistakes
• Educate and influence change
• Motivate and Support
• Encourage creativity & innovation
• Recognition and Appreciation
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Continue …. Company Wide Cultural Transformation

9. Productivity in Manufacturing Plant: People Development 2
Empowerment
and
Engagement
2
Behavioural change
• Authority
• Trust
• Pride
• Educate or Influence
• Mistake is not a sin. But a learning process
• Conventional thinking versus out of box
• Support & groom or develop employee
• Recognition, Motivation & Encouragement
• Choice of words. Constructive vs offensive
• Listener with patience & tolerance
• Attitude vs skills & knowledge.
• Avoid opinion or assumption. Do homework.
• Management philosophy. Who is most important ?
• Communication :-
- Share timely info
- Body language
- Project - understand & believe is achievable
- Engage all stakeholders
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10. Productivity in Manufacturing Plant: People Development 2
• Production
Operators as QC
inspectors
• Zero Tolerance
• Subject Experts
• Support projects
Training
Coffee
Meeting
Individual
Success Factor
• Operators
• IDL and IL
• Managers
• Hard working
• Work Smart
• Visibility
• Positive attitude
• Calm & Confident
• Independent &
Reliable
• Sense of urgency
• Initiative and
resourceful
• Systematic
approach.
Empowerment
and
Engagement
2 Incentive &
Recognition
• Best Line Leader
• Best Prodn Line
• Best Operator
• Zero Tolerance
• Star Award
• 3Rs Program
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11. Executive Working Experiences
Managing Director. Astec Custom Power Private Ltd (Kuantan, Malaysia) 1991 - 1997
1. Managed Power Supplies and Magnetic manufacturing plants with combined workforce at peak of 5,000 employees.
2. Major improvement - Productivity and Quality with all time high Positive P&L
3. Implemented Automated Testing Equipment using PC Based system.
APAC Director. (Quantum, Maxtor & Symbol Technology) 1997 – 2009
1. Managed Hard Disk drives Configuration and after sales support for Asia Pacific region.
2. Repair and after sales support for Symbol Scanner products.
3. Major in Reverse Logistic and setup service centres in Asia Pacific like China, Korea, India, Vietnam, etc
Managing Director. (Emerson – Artesyn ) 2011 – 2020
1. Setup magnetic manufacturing plant in Vietnam in 2011.
2. Managed Power Supplies and Magnetic manufacturing plants in Philippines with combined workforce at peak of
10,000 employee.
3. Transformed company with cultural change, positive P&L performance and digitally transformed to Industrial 4.0
4. Major improvement in Conversion cost through Lean/Productivity, Space optimization and People empowerment.
5. Introduced innovation and submitted several productivity related Patents.
6. Most preferred low cost and high tech manufacturing site by customers with huge growth in revenue year on year.
7. Received many PEZA awards given out by the President of the Philippines.
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12. Services Available
Onsite Consultation
1. Training
1. Lean & Productivity for Industrial Engineers (IE)
2. Lean & Productivity for Factory Engineering and Quality folks
3. Lean & Productivity for Production supervisory staff
4. Management and Behavioural Training.
2. Project
1. Select a product line as project for productivity improvement
2. Improve material flow and layout to optimise Line UPH (Unit per hour).
3. Line balancing using OSA (Operation Sequence Analysis)
4. Introduce mechanization and/or Automation
5. Introduce Single piece flow or Flow line production.
Automation (Design, fabrication, installation & implementation)
1. Software Automation
2. Processes Automation
3. Test Automation
Page 11 of 12

13. Services Available
Automation (Design, fabrication, installation & implementation)
1. Software Automation
1. Machine Maintenance Management System (MMMS)
2. Product Process Management System (PPMS)
3. Paperless transactions
2. Processes Automation
1. 3D animated Work instructions
2. Mechanical automation
3. Test Automation
1. Test Multiplexing
2. Universal Testing without unique Test Fixtures
3. Dynamic Test for Significance
4. Automated Image Recognition
5. Thermal testing proactively filter out potential Design, Process or component thermal
defects Page 12 of 12