FA Malaysia
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This presentation discusses factory automation in Malaysia. It begins by defining factory automation as automated machinery that executes manufacturing tasks. It distinguishes between standard machines available for purchase and customized machines designed for special processes. The presentation then provides a history of factory automation in Malaysia, noting it began in the 1980s through foreign companies but is now also adopted by local companies. It acknowledges encouragement for more factory automation in Malaysia due to issues with manual labor but regional competition. Finally, it mentions emerging trends in industry 4.0, IoT, and cloud-based technologies that further improve manufacturing costs and outputs.
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Toyota has a global supply chain management system focused on lean manufacturing principles. They aim to produce only what is needed through just-in-time production and a pull system. Toyota designs their production system and supplier relationships to eliminate waste and variability. This includes designing parts for commonality, limiting optional variations, and sourcing locally for flexibility. Toyota audits suppliers using metrics focused on quality, cost, delivery and their implementation of Toyota's philosophies. Their logistics network transports parts through local and global inbound routes planned through optimization software.
Additive manufacturing in the automotive industry
1) Additive manufacturing (3D printing) allows for the production of complex, lightweight parts and is increasingly being used in the automotive industry.
2) It provides benefits like faster prototyping, supply chain transformation through on-demand production, and cost savings through lightweight materials.
3) Major automakers like Ford, BMW, Volkswagen, and McLaren are investing in 3D printing and have implemented the technology for prototyping, tools and fixtures, and some production parts.
A Profile of Toyota’s Production Systemprofile W90C18Jan.docx
A Profile of Toyota’s Production System
profile W90C18
January 28, 2010
Published by WDI Publishing, a division of the William Davidson Institute (WDI) at the University of Michigan.
©2010 Scott A. Moore. This profile was written by Professor Scott A. Moore, Ross School of Business at the University of Michigan, as
the basis for class discussion rather than to illustrate either effective or ineffective handling of an administrative situation.
Early History
Kiichiro Toyoda founded the Toyota Motor Company in 1937.1 The company, headquartered in Toyota
City, Japan, grew to a market capitalization of $138 billion by early 2010,2 number 10 on the Fortune Global
500. It was the largest car company in the world,3 having produced 8.9 million vehicles worldwide in 2008.4
Before founding the company, Toyoda was denied the opportunity to head his family’s mechanical loom
business. Looking for alternatives, he set his sights on building cars. He attracted his cousin, Eiji Toyoda,
to be his understudy and partner.5 They were both impressed by the industrial might of US companies during
the war and wanted to see them in operation. In the early 1950s, Eiji Toyoda traveled to America in order
to study Ford’s immense River Rouge plant just outside Detroit, Mich. He was impressed by the size of the
plant but noted many inefficiencies,6 including large amounts of both inventory and rework to fix production
mistakes.7 Some good did come from this trip, but it was from a visit to a Piggly Wiggly supermarket. “
[T]he delegation was inspired by how the supermarket only reordered and restocked goods once they had
been bought by customers.”8 This would become the kanban system, part of the inventory restocking policy
that would become world-renowned.
The TPS
While growing the company in Japan between 1949 and 1975, Toyota management—primarily Taiichi
Ohno, Shigeo Shingo, and Eiji Toyoda9—worked on improving the company’s logistics and production
processes, especially as they related to minimizing inventory, involving employees in the process of managing
their jobs, and defining the manufacturing process so that it could handle multiple products easily.10 The
result of their work became known around the world as the Toyota Production System (TPS).
TPS is “an integrated socio-technical system…that comprises [Toyota’s] management philosophy
and practices. The TPS organizes manufacturing and logistics for the automobile manufacturer, including
interaction with suppliers and customers.”11 It has two foundational concepts:
For the exclusive use of W. Gu, 2017.
This document is authorized for use only by Wenlong Gu in MGT545-141 taught by Ivana Zilic, DePaul University from September 2017 to November 2017.
2
A Profile of Toyota’s Production System W90C18
1. “One of these is the ‘just-in-time production,’ an especially important factor in an assembly
industry such as automotive manufacturing. In this type of production, ‘only the neces.
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The document provides an overview of Uno Minda, an automotive components manufacturing company. It discusses Uno Minda's history, operations, products, customers, quality processes, and facilities. Key points include:
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- The company operates various divisions and has subsidiaries/joint ventures. It focuses on technology, innovation, and sustainability in its production methods.
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FA Malaysia
- 1. FACTORY AUTOMATION Malaysia *This presentation contain 8 slides 1
- 2. What is Factory Automation? -Automation in manufacturing refer to an automated machine that executes certain task. -The task may be part of the manufacturing process. 2
- 3. Different between Standard machine and FA machinery Type of machinery use in manufacturing. 1) Standard machine 2) Customise machine (Factory Automation machinery) 3
- 4. Standard machine -Example: Printer, fax machine, stamping machine, injection moulding machine, labeling machine, packaging machine etc. (That we can buy from catalogue) -Standard machine are mass produced due to it design to run core process or standardised process. This lead to high demand of the machines. It OEM cost can be greatly reduced. 4
- 5. Customise machine -In general, a customise machine design to run some special process where no standard machine can perform. -These machine are not in catalogue. -These special process may need to run before, in between or after standard machine's processes. -Customised machine often improve production efficiency yet quality of the products. For example, implement of QC system like Vision system or measurement unit. Thus, standard machine performance can be monitor. -Automation machinery can be design and made by request to suit different needs. 5
- 6. FA in Malaysia, History -Factory automation in Malaysia started since 1980s, when foreign company bring in their production line here. Company like TAM, an OEM company from Japan, open its branch here to support Matsushita Group for it FA & engineering needs. -Foreign company are well know for implements FA to their production line. -Today, local OEM & engineering company well adopted FA technology (Industry 3.0) from Japan or Europe. -Compare to region country like Thailand, Indonesia, Vietnam or China, Malaysia started FA early. But mainly by foreign company. -Region country are catching up, especially China & Thailand. 6
- 7. FA in Malaysia, Current Encouragement to implement FA to production line often appear in news, forum discussion or social media. While many of our production line operate manually by foreign worker, many issue have emerged. 1) Uncertain policy from gov. 2) Rising HR cost. 3) Inconsistence quality & output. 4) Difficult work flow implementation & standardisation, etc. 5) Our manufacturing sector not able to compete with region country in terms of quality & output. 7
- 8. FA Trend & what is coming -Industry 4.0, big data, IoT & Cloud. -Company in Germany like BMW & Kuka Robotic had started implement it. -By new technology, manufacturing cost, wastage, production cycle, stock & output are effectively improved. -Factory are ship back to Europe, competence against China's low cost manufacturer. 8
- 9. End of presentation. Thank you. Best regards, Chai FA Project manager SOFKON SYSTEM Linked In sofkon_system@yahoo.com *comment & feedback are welcome.