PROTON OH PROTON!!! (Part 2)

For this post i would like to used English. I hope that u guys understand. Sorry if my English broken. So these are the details that my friend Prem obtain while the visit in Proton.

    ·  We were guided by Mr. Irwan in to the production line

    ·  Follow Toyota system of assembling which is line time accuracy.

    ·    From 1985 they following the same system of operation .now currently they using 5.72 man Hr/unit

Trim and final shop process plan

·         1^st  the empty body will enter the conveyor line

·         Production line  output capacity is around 150 k/year

·         Currently they were producing car model num:P2-11 A/ P2-11C.called as proton saga FL

·         Average output is 40 unit / hour

·         Current l\line speed is 38 unit / hour

·         It takes around 94.7sec /unit

·         The line efficiency is 95%

·         Total process time is 19.234 sec for each process

·         Man power is 207 workers directed by 63 supervisor   

·         They are using 1424 system to monitor each station .

·         Its like 1 supervisor , 4 team leader , 24 man power.

·         Tanjong malim plant is working on 60% automation system and hicom sha alam plant is 30% automated system.

·         Stamping , body assembly , painting and trim and finalization is the main process a car will go thru.

Wagon dolly system

·         It’s a system where they will manage their components on their station.

·         It’s a system where replacing the finished part without any disturbance to the workers.

·         Its working on time basis method.

·         Every 15 min the fitter will purchase new product to their station.

·         If he cant finis his work on given time, the next station worker will help him doing his job done.

·         For a new fitter or operator , at least he will follow his supervisor for one week.

·         He will not do any work just observation only for the entire week.

·         Every end process have a gate.

·         There they will have a QC check.

·         They using the FIFO (First In First Out) system to monitor the quality of the product they make.

The encouragement they provide for the workers. 

·         To encourage their worker, the management have given prizes to the designer who design a system where its help the worker to reduce their work load.

·         Example: like a worker need to bend down every time to fit their part in the car, so they design a pulley system where it will bring the required part near to the worker so that he wont to bent down to do the task every time.

·         It also reduce the risk and the work load of a worker. Other than that its also save the time consume by each process.

Satellite line

·         In this line, they are doing face out units for small orders like for government order.

·         They  are capable to produce 4 units per hour.

Sub line

·         In this line they were fitting engine and transmission compartment for the car.

·         In this line they also fit the gear system also.

·          In engine docking area, two person will work on this part.

·         Both also must work synchronously to mount the engine to the correct position.

·         Each person works under 95 sec to finish their task. So times by 2 equal to 190 sec.