A Visit to Proton

 

31 March 2011- A Visit to Proton Manufacturing at Shah Alam

  Depart Time : 7.10 AM

Arrived Time : 9.00 AM

Time : 5.00AM

Having our breakfast at Restoran Subaidah

Time : 7.20AM

The day look dark because morning just have a heavy rain

                                   Sleep...ing in the bus             Lecture  full fill his time by reading..thumb up!!!

Time : 9.00AM
Venue: Shah Alam Proton  

Representative of PROTON company welcome us for the visiting

Student entering the building of PROTON

Time: 9.05AM

Representative of respective company was giving us a simple briefing about the PROTON Company and following by a video clip. Before display the video clip, our beloved lecture En.Sadhiqin bin Mohd Isira was represents our university thank you to the company for allowing us pay a visit to Proton.

Video clip about the introduction of PROTON

                            

                                                                         Part 1

                                                                 Part 2

Time: 9.25AM

Production Visit

At 1st, we are giving a briefing by En Abdul Rahman about the overview of the Trim & Final Shop Process Plan.

          Current line: 38 units / hours

          Production Output: 40 units / hour @ 90 second

          Model: P2 – 11A / P2 -11 O

          Man Power: 207 man (Direct)

                            : 63 man (Indirect-Such as supervisor ) 

          Total Process Time: 94.7 sec / unit 

TRIM 1

Lead by: En. Irwan (26 years experience in PROTON manufacturing production line)

First of all, he explain the basic management of the man power 

After that, we are proceed to the next section which involved the door insertion and painting on the body of car.Once the body are finish painting, have to remove the door from the body.That is because:

                          *Time saving

                          *Avoid defect ( Such as scratch happening during process flow) 

In the Shah Alam Proton plant, there are only involve 30% of the machine automated operating.Comparing to the Tanjung Malim plant there are equipped with 60% of the machine in automated operating.

From the information given by En.Irwan, the total long of the flow of the system is 5.5 meter and they have to complete it within 94.7 sec.In case not hurry to finish insert the part can use the "wagon dolly" to slow down the speed in the production line

In addition information, for those new worker there will work under 1 week supervise by their team leader and supervisor.If still have problem, they need to retrain and looking own self for improvement. 

TRIM 2

There are QC gate 1 existing at here to check the performance of the insertion parts have been done. The system applying here using FIFO.

After pass the QC gate 1, will entering QC gate 2.During the product at this section will have a double checking on the product.

CHASIS 1

In this section, the parts will be fix on the body more to the under parts of the car.

Such as: Oil tank insertion.

** The design of the machine handling the "Oil tank" won the gold prize during 2010 among the whole production lines.   
** For sure, there will be a TPM (Total Productive Maintenance) to check and ensure the products have been produce having a long life span.

Addition:

Beside the line of CHASIS 1, there have a “Satellite line”. This production line is more to the manual handling because it involves low volume at the production output

Such as: Proton Perdana which support the government car all the time. Capacity of the production line is 4 units per hour. 

CHASIS 2                                                                                                                   

Part 1

Involving:                   *   Automatic Engine Dropping

*   Engine Mounting

*   Tires Broadcasting

*   Tires Synchronizes

*   Robot Arm put Glue on the Window Glass

*   Transferring of Window

*   Insertion of Seat

*   Insertion of Steering

Part 2

Involving:                    *  Fill Water in the Water Tank

*   Fill Brake Oil

*   Fill Petrol Oil

*   Fill Power Steering Oil

*   Fill Air Condition Gas

*   Fill Clutch Oil

*   Others small material in term of liquid

After completing in the CHASIS 2, the doors were insert back to the body of the car.

Testing (QC Main Plant)

Will perform the finalize checking such as:

                                   

                                    *Checking Overall Outlook

*Checking Overall Functionality

*Checking Ekzos

In the Dynamic area perform checking as:

*Checking Alignment

*Checking Overall parts such as wiper

*Checking Speed 120km/h on the spot

*Checking the Bottom of Car any Leaking by Naked Eyes

Finishing

Any issues about the car performance will having a detail troubleshooting at here and recovery the problem existing.

Time: 11.00AM

We finish the industrial visit and having the food provide by the company.

After having our food, lecture on behalf of university giving souvenir to the PROTON Company. 

Time: 11.25AM

After that, we were having a photo section among all participants and giving opportunity to look around the corner in the building which selling the key chain or some product of PROTON. 

Time: 11.40AM

Finally we check out from the PROTON Company.

Before leaving the company we are having a photo with the model of car.