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Wednesday, November 27, 2013

Perodua's new Rawang plant to be world class

Source: http://www.btimes.com.my/Current_News/BTIMES/articles/perod26/Article/
REPLICATION OF JAPANESE FACTORY: Improved defect per unit rate of 0.05pc

SECOND national carmaker Perusahaan Otomobil Kedua Sdn Bhd's (Perodua) new manufacturing plant in Rawang, Selangor, which is currently under construction, is set to be the first world-class highly-efficient car manufacturing plant in the country.

Perodua executive director Zainal Abidin Ahmad said the RM790 million factory, a replication of Perodua's Japanese partner Daihatsu Motor Co's high-tech plant in Fukuoka, Japan, mirrors the company's serious efforts to be a competent global player.

"The new plant will have an improved defect per unit (DPU) rate of 0.05 per cent, which is a world standard. We plan to achieve world-class level through this new plant. This shows that Perodua has come a long way to be where we are today.

"Through our transformation activity, which started two years ago, we've seen a lot of improvements in Perodua's operation, where we managed to gradually reduce our operation cost from 15 to 30 per cent. With the new plant, we are very much at par with certain companies at the international level," he said during a media trip to Daihatsu Motor Kyushu plant recently.

The Daihatsu Motor Kyushu plant, which started operation in November 2007, was specially designed to produce light vehicles. It rides on the "Simple, Slim and Compact" concept, which allows the plant to annually produce the same number of vehicles as the older Daihatsu plant but using half of the latter's floor space.

Due to the compact structure of the plant, power consumption for the air-conditioning systems and other equipment in the building is reduced.

Zainal Abidin said Perodua is aiming to emulate at least 85 per cent of the Fukuoka plant's system for the new plant in Rawang, as certain aspects still need to be done according to local requirements and environment.

"For example, the plant in Fukuoka has a cool environment because of the local weather. The weather is hotter in Malaysia and so we have to install enough air-conditioners in the plant to make sure that our workers can work in a comfortable environment, which in turn will help increase productivity," he added.

Zainal Abidin said Perodua's new 65,000 sq ft plant, which is located next to its plant in Sungai Choh, will only focus on manufacturing new models, which includes those existing models that will go through a full-model change.

"At the moment, the new plant is for new models and also for what we call full-model-change. So, our next model, which we will introduce soon, will be manufactured in this plant," he said, adding that Perodua plans to manufacture one model from the plant for a start.

He said the company has allocated up to RM1.3 billion for the plant, inclusive of the cost of the plant as well as the assem-bly line for one model with an annual production capacity of 100,000 units for one shift.

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