The document summarizes a shop attachment program at an assembly shop from December 5-12, 2016. It includes the manufacturing process flow, assembly layout, mission and vision statements focusing on developing professional skills and assembling high quality cars on time and at low cost. Key elements of safety, quality, cost, delivery and moral standards are outlined. The specific process, personnel in charge, abnormalities found, and countermeasures proposed for a tire installation station are then detailed.

1. Shop Attachment Program
Assembly Shop
5th December 2016 – 12th December 2016
Redza Bin Amin Suggun
Trainee DEP 4th (Group 6)
719186

2. Manufacturing Process Flow
Press
Shop
Body Shop Paint Shop Assembly
Quality
Control
Pre-
Delivery
Distribution
Dealer &
Branch
Customers
Logistic CMK Shop

3. 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

4. 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.

5. 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

6. Person In Charge
• Supervisor: Abdul Halim Nyan
• Team Leader: Mohd Sharil
• Team Member: Mohd Hafeez
Station / Process
• Process: Tyre LH
• Station : STN – 14

7. Process Involved
• Myvi
i. 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)
• Alza
i. 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)

8. 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 properly
Machine
•The compartment is too far.
•Handling of impact.Material
•Method of lifting the tyres.
•Did not follow sequence for nuts attachmentMethod

9. 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

10. 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.