Shop Attachment ProgramAssembly Shop

5th December 2016 – 12th December 2016Redza Bin Amin Suggun

Trainee DEP 4th (Group 6)

719186

Manufacturing Process Flow

Press Shop Body Shop Paint Shop Assembly

Quality Control

Pre-DeliveryDistribution

Dealer & Branch

Customers

Logistic CMK Shop

Assembly Layout A2 Line

Trim Line

Final Line

Chassis Line

S/A Radiator

PBS

Door Line

Quality Inspection

Station 12

Station 13

OK

OK

NG

NG

Mission & Vision

• Mission– Develop professional people which are able to

respecting the rules, sustain the machine, creating effective method and securing the materials.

• Vision– Assemble the car with the highest quality, within

the time period and at a lower cost.

Key Elements

Safety• Wear appropriate

PPE• Use the correct

method or technique (ergonomic)

• Kiken Yochi• Use Stop, Call,

Wait

Quality• Follow the rule

and S.O.P. • PokaYoke –

Mistake Proofing• SIIP• Quality

Classification• Defect Control

Rule• BIQ Forms

Cost• Eliminate or

reduce 7 Muda

Delivery• Deliver OK

products for customers.

• Timely delivery• Ensuring the

sequence are correct

Moral• Follow 9

PERODUA ethic codes

• Obey BEN 10

Person In Charge• Supervisor: Abdul Halim Nyan• Team Leader: Mohd Sharil• Team Member: Mohd Hafeez

Station / Process• Process: Tyre LH• Station : STN – 14

Process Involved

• Myvii. Take and install 4 pcs grommet for upper and lower S/Radiator (SS

no 2, 3 & 4)ii. Detach 4 pcs bolt upper support Radiator (SS no 5)iii. Take and install tyre RR LH (SS no 12 & 13)iv. Install 4 pcs Nut to Tyre RR LH (SS no 14)v. Push Complete button (SS no 18)

• Alzai. Take and install 4 pcs grommet for upper and lower S/Radiator (SS

no 2, 3 & 4)ii. Detach 4 pcs bolt upper support Radiator (SS no 5)iii. Take and install tyre RR LH (SS no 12 & 13)iv. Install 4 pcs Nut to Tyre RR LH (SS no 14)v. Push Complete button (SS no 19)

Abnormalities

• Talking during process• Sign of back painMan• Space between nut runner and conveyor is small• Tyre machine is low • Nut runner wire is not covered properlyMachine• The compartment is too far.• Handling of impact.Material• Method of lifting the tyres.• Did not follow sequence for nuts attachmentMethod

Counter Measure

• Frequent supervision from TL is needed.• Enforcement of wearing back supportMan• Increase platform width for the team member to roam / move.• Increase the height and inclination of the machine• Refurbish the wire cover.Machine• Rearrange the compartment.• Provide mobile impact holder.Material• Follow the correct S.O.P, method and sequence. • Frequent supervision is needed. Method

Conclusion

• Knowledge & Experiences gained through this shop attachment:– Process involved in assembly shop– Qualities demand by assembly shop (SQCDM)– How does TM operate during process.– Abnormalities findings (Observation & Experience)– Presenting ideas & Proposal for countermeasure.