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1. Company Profile (Product & business strategy ,TIV, market shares, production forecast) ~ Introduction. 2. Perodua sales, order flow and plant layout ~ Business model. 3. Implementation of TPS (Toyota Production System) in Perodua ~ Kanban, Standardize Work, 5S, Kaizen. 4. Perodua assembly line (Line A1 & Line A2). 5. Globalization challenge and future trends. 6. Recommendation. 7. Conclusion.
Table Of Content
1.0 Introduction
Introductio n
Alza Myvi
iva : 660cc-1.0cc : 13 variant : 6 color : Price RM27k RM43k Myvi : 1.3cc-1.5cc : 14 variant : 7 color : Price RM52k-RM63k lza : 1.5cc : 6 variant : 6 color : Price RM56k-RM70k summary 3 model 33 variant, 7 color and price from RM27k-RM70k
usiness strategy.
ocus : Cost leadership, people car, compact car, small car arget customer : For 2nd car, student, fresh graduate, small family. elling point : Fuel efficiency, acceptable quality, low maintenance cost, y to handling.
1.2 Product life cycle and type Introductio n of new product development.
Sale Maturity of product
Type of new product development at Perodua : Modification and Addition (not new concept). Based on platform develop by Daihatsu Motor Japa
1 Facelift no1
3 Facelift no2
Year
1.3 Total Vehicle Market In Malaysia As Of Nov 2011 (551,018 unit) Overview Introduction 2011 sales of vehicles.
Market Leader
1.4 Percentage Market Share Of Introduction Automotive Industries In Malaysia As Of Nov 2011.
1.5 Market units comparison as of Introduction Mar 2012. Total Industries Vehicle (TIV) Actual TIV TIV Mar'12 : 53.6K
Units (x 1,000) 70.0
60.0
50.0
40.0 New Lending Guideline from BNM 30.0 Impact Thai Flood
Year 2011
Cumm.
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec TIV 54.8 40.4 63.3 50.9 46.0 41.8 50.3 58.4 44.4 53.6 48.3 48.0 600.1
54.8 95.2 158.4 209.4 255.4 297.2 347.5 405.8 450.2 503.9 552.2 600.1
2012
Cumm.
138.5
1.6 Market units comparison as Mar Introduction 2012. Market Share Movement Actual
P2 Market Share
Mar 30% YTD Mar 32%
35%
50%
40%
30%
29% 24%
31%
20%
10%
32.3%
25.3% 16.3% 5.8% 1.5%
Proton
24% 19%
Mar'12
YTD Mar'12
M arket M o d e l V o lu m e V s 2011 Sh a r e M yvi 22.2k 2 4% +4% Sa ga 1 7 .2 k 1 8 % -1 6 % V iva 12.8k 1 4% -19% P e r so n a 9 .6 k 1 0 % -2 2 % V io s 7 .9 k 8 % +8 % O th e r s 2 3 .7 k 2 5 % -3 4 % T o ta l 93.4k 100% -18%
8.0k
7.7k
6.5k
6.0k
4.8k
3.5k 3.0k
4.0k
2.0k
1.8 Market units comparison as of Introduction Mar 2012. Multi Purpose Vehicle (MPV) Actual
Units (x1,000) 5.0k
Mar'12
YTD Mar'12
M arke t M o d e l V o lu m e V s 2011 Sh a re A lza 9.7k 40% +15% E xo ra 6 .5 k 2 7 % +1 8 % G r a n d Liv in a k 1 2 % -1 2 % 3 .0 A v a n za 2 .0 k 8 % +1 0 % In n o v a 1 .4 k 6 % -1 2 % O th e r s 1 .9 k 8 % -2 4 % To tal 24.4k 100% +7%
4.0k
3.5k
3.0k
2.0k
1.0k
2.0 Perodua production six month Introduction rolling forecast. Production Summary Total P rodn ASSY Line On = 13,500 units
M ay12 DO / EXP DI = 13,500 units
Oct 17 4,950 7,930 3,000 15,880 Est. M odel Apr'12 M ay Jun W orking Days 19.5 19 21 Viva 5,034 4,600 5,110 M yvi 7,333 7,400 8,800 A lza 3,700 1,500 3,100 Total 16,067 13,500 17,010 P ro ductio n DO P lan Jul Aug Sep 22 16 20 5,540 4,690 5,550 9,890 7,310 8,990 3,800 2,700 3,450 19,230 14,700 17,990
Average prodn 18.0k per month, 900u per day. Note: Production DO plan is included recovery or advance production.
otes: Each variant of model have specific part number for it component. (Example umper Myvi Std variant color black/white : XXXXX-XXXXX-AB/C) Booking from customer will be stored in the system and production will start produce the car based on the order. Ordering of part to all supplier will be generate in the system and the sequence ll be follow accordingly. The standard and normal lead time from ordering to deliver the car to customer i bout 5 days.
2 Body Shop
Paint Shop
Press Shop
Corporate Building
1. 2. 3. 4. 5.
es: erodua start to implement some of the basic concept of TPS from year 2002. t the same time Perodua also implement TPM.
Cost
Profit
Basic Principle
Heijunka as precondition: 1. Make process as flow 2. Decide tact by necessary volume. 3. Pull out from next process.
Machine maintenance system consist of the entire life of equipment in every division Participation from all working level i.e. from top to bottom Implementation through autonomous small group activities
1 . U s in g P u ll s y s te m . 1 . R u n n in g c a rs is re d u c e d . 2 . L o t s ize is s m a ll. 2 . A c c id e nt c a n b e re d uc e d . 3 . Im p le m e nt K a nb a n a nd . M is s ing p a rts c a n b e le s s . 3 J und a te s ys te m to s a ve 4 . L e a d tim e to P D I is le s s . s p a c e a t line . 5 . M is s ins p e c t c a r c a n b e e lim ina te d d ue to le s s c a r.
P DI
Assy Cm k
1 . E ffic ie n c y o f S td W o rk e lim in a te 3 m u d a . 2 . F u ll a n b a n K im p le m e nta tio n. 3 . M in o m i s u pa t ly s id e . p line 4 . H e iju n k a d uc tio n line . p ro 5 . J id o ksays te m to a vo id d e fe c tive ve hic le s .
Perodua Ordering and Receiving System For Local BASIS PART BY PART Part (Year 2004)
Vendor s
PPC Dept.
DI as reference
Vendor s
E-Sims
Vendor s
Vendor s
Logistics Dept.
Hikitori Kanban
Production Line
Vendor s
MILK RUN
Vendor s
Vendor
BEFORE
AFTER
rovement items : hange from carton box to TP (Toyota Polybox). rdering based on customer ordering (pull system). o need to open and dispose of carton box. P polybox is returnable. art easy to see and differentiate. fo system had been implemented. aximum and minimum quantity of part is based on level and quantity at storage a ual control.
efits. ave cost in terms of packaging (recycle and reuse of polybox) ~ Previously carton ave operator time to open, count and check part inside the carton box. etter visual control. educe cost due to secondary defects such as old stock, wrong part and part missin
Fifo control
te : Each part have the specific area based on the area that need to supply at the oduction line. Fifo system implemented using gravity roller stacking part storage from behind ke out from front. Specific parking for buggy car, the parking area specifically tally with e quantity of buggy car. Visual control on buggy car missing or breakdown.
501
502
503
504
505
506
A1 Line
S
105 106 107 108 109 110 111 112 113
S/A ENGINEA1 R E P A I R B A Y
S/A CTR A1
JUNDATE A1
HEAVY REPAIR
3 R T C A / S
508
Trim 2
146 145 144 141 140 139 138 137 136 135 134 133 132 131 130 129 128
JUNDATEZ ONE B
154 153 152 151 150 149 18 147
509
IP LINE A1
510
End Chassis 1
160 161 162 163 164 165 166 167 168 169 170 174 175 176 177 178
511
Final
179 180 181 182 183 185 186 187 188 189 190 191 192 193
REPAIR BAY A1
512
513
3 L A N I F P S
514
S/A CTR A2
SPS FINAL
SPS DOORA1
SPS DOORA2
290 M
REPAIR BAY A2
515
516
Final
354 355 356 357 358 359
End
517
520
REPAIR BAY
326 325 324 323 316 316 316 316 318 317 316 315 314 313 312 311 310 309 308 307 306 305 304 303 302 301 300 299 298 297 296
Start Line A2
521
REPAIR BAY
S/AENGINE A2
S/A ENGINE A2
A2 Line
SPS TRIM S/A GLASS S/A PEDAL IP LINE A2
Trim 1
522
523
M
SPS TRIM
2.9 TPS Practice (in Perodua) (Example) Before & After Kaizen Implementation at
Perodua Assembly Line (2002)
Location: AT1-9 Process Name: S/A Ventilator
Identified muda: - Process flow crossing (9 to 10) Position No. & Surrounding
BEFORE
2 1
Objective : 1. Reduce walking and pick-up time 2. Reduce manpower 3. Improve process arrangement 4. Reduce space
IMPROVEMENT
PIC 1
PIC 2
Before
1. 2. 3. Racking Size = 2400 mm No FIFO system 2 units required each for Kancil M/T and A/T
After
1. 2. 3. Racking Size = 800 mm With FIFO system 1 unit required each for Kancil M/T and A/T
IMPROVEMENT
PIC 1
PIC 2
Before
1. 2. 3. Wire stacked up No FIFO system Double location Supply (LG) & Assy pick-up
After
1. 2. 3. 4. MINOMI style FIFO 5S improvement No more double location
IMPROVEMENT
KELISA
PIC 1 RR View PIC 2 FR View
Before
1. 2. 3. Big space requirement 2300mm Operator need to dispose empty boxes Operator need to open carton boxes
After
1. 2. 3. Smaller space requirement 1 rack for both Kancil & Kelisa - 1000mm No empty boxes Reduction in process time through opening & disposing
IMPROVEMENT
Racking Kaizen no. 4 Courtesy Switch & S/A Fuel Pipe Parts
Before
1. 2. 3. MUDA on walking available 5 seconds No FIFO system Separate racking from main part
After
1. 2. 3. No more walking MUDA on S/Assy rack S/A parts on the same rack as Fuel Pipe With FIFO on parts delivery