An improvement study of outgoing materials handling at Perodua Engine Manufacturing Sdn. Bhd. (PEMSB) Plant in Sg Choh Rawang, Selangor

Abstract

An outgoing material handling improvement conducted in Perodua Engine Manufacturing Sdn. Bhd. (PEMSB) plant in Sg. Choh Rawang applies engineering theoretical knowledge into practice. Integration of both Toyota Production System (TPM) and Lean Thinking are made, in order to driven down the current problems and wastes in PEMSB plant. The main concerns of this project are to improve current process and arrangement of Jundate station along with its sub-assembly stations. The objective, scope and importance of this project are written and explained in chapter 1. Subsequently chapter 2 present literature of this project where the definition, introduction to Jundate K3/K5 station and other elements related to the station is outlined. Jundate station plays an important role in engine production at PEMSB plant. This station is responsible in supplying basis components in engine manufacturing like cylinder block, crank shaft and crankshaft to their belonging sub-assembly station. Besides that; analysis tool such as Movement/Operation (MO) ratio, Handling Equipment Utilization (HEU) Ratio and NIOSH lifting equation are also briefed in chapter 2 as well. Chapter 3 will explained the methodology of the whole project; starting from the understanding of project title until presentation stage. Next is chapter 4; where each problem related to Jundate station (based on factory observation) are listed and discussed in details. Evidences of problems in Jundate station are revealed by analysis tools that already discussed in chapter 2. As a result to detail analysis in chapter 4, chapter 5 proposes the improvement and implementation in Jundate station. Propose improvements are in the forms of station arrangement, working process, facilities utilization and other kaizen activities. The final results and conclusions of this project will be documented in chapter 6. This final chapter will concluded the whole study of improvement activities and some recommendation for future project study. Continuous improvement within quality, material handling, and work procedures is crucial in order to eliminate waste and achieve well working lean manufacturing system. Establishment towards this goals required full support from workers and top management.