Perodua Presentation. 26 April 2012
Perodua Presentation. 26 April 2012
Perodua Presentation. 26 April 2012
Table Of Content
1. Company Profile (Product & business strategy ,TIV, market shares, production forecast) ~ Introduction. 2. Perodua sales, order flow and plant layout ~ Business model. 3. Implementation of TPS (Toyota Production System) in Perodua ~ Kanban, Standardize Work, 5S, Kaizen. 4. Perodua assembly line (Line A1 & Line A2). 5. Globalization challenge and future trends. 6. Recommendation. 7. Conclusion.
1.0 Introduction
Introduction
Viva
Alza Myvi
1. Viva : 660cc-1.0cc : 13 variant : 6 color : Price RM27k RM43k 2. Myvi : 1.3cc-1.5cc : 14 variant : 7 color : Price RM52k-RM63k 3. Alza : 1.5cc : 6 variant : 6 color : Price RM56k-RM70k As summary 3 model 33 variant, 7 color and price from RM27k-RM70k
Business strategy.
1. Focus : Cost leadership, people car, compact car, small car 2. Target customer : For 2nd car, student, fresh graduate, small family. 3. Selling point : Fuel efficiency, acceptable quality, low maintenance cost, easy to handling.
1.2 Product life cycle and type of new Introduction product development.
Sale Type of new product development at Perodua : Modification and Addition (not new concept). Based on platform develop by Daihatsu Motor Japan
Maturity of product
1 Facelift no1
3 Facelift no2
Year
1.3 Total Vehicle Market In Malaysia As Of Nov 2011 (551,018 unit) Overview 2011 sales of vehicles. Introduction
180000
161777
160000
148124
140000
120000 100000
81548
34457 12756 8537 6216 6782 5352 5330 4402 1065 1915 0 1523 1595
Introduction
29.0%
14.0%
26.0%
1.5 Market units comparison as of Mar 2012. Introduction Total Industries Vehicle (TIV) Actual
TIV
Units (x 1,000) 70.0
u
Year 2012 (Est. TIV 615k)
MAA Report
60.0
50.0
40.0
30.0
Year 2011
Cumm.
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec TIV 54.8 40.4 63.3 50.9 46.0 41.8 50.3 58.4 44.4 53.6 48.3 48.0 600.1
54.8 95.2 158.4 209.4 255.4 297.2 347.5 405.8 450.2 503.9 552.2 600.1
2012
Cumm.
138.5
1.6 Market units comparison as Mar 2012. Introduction Market Share Movement Actual
P2 Market Share
50%
40%
33%
34% 30%
30%
20%
10%
YTD Mar'12 45 k 35 k 23 k 8k 2k
2nd Qtr 2011
Proton
24% 19%
Mar'12
YTD Mar'12
Model Volume 22.2k 17.2k 12.8k 9.6k 7.9k 23.7k 93.4k Market Share 24% 18% 14% 10% 8% 25% 100% Vs 2011 +4% -16% -19% -22% +8% -34% -18%
u
7.7k 6.5k
8.0k
6.0k
4.8k
v
3.5k 3.0k
4.0k
2.0k
1.8 Market units comparison as of Mar 2012. Introduction Multi Purpose Vehicle (MPV) Actual
Mar'12
YTD Mar'12
Model Alza Exora Grand Livina Avanza Innova Others Total Volume 9.7k 6.5k 3.0k 2.0k 1.4k 1.9k 24.4k Market Share 40% 27% 12% 8% 6% 8% 100% Vs 2011 +15% +18% -12% +10% -12% -24% +7%
4.0k
u 3.5k
2.4k
3.0k
2.0k
1.3k
1.0k
1.0k 0.5k
Introduction
Introduction
Average prodn 18.0k per month, 900u per day. Note: Production DO plan is included recovery or advance production.
Ordering flow
Notes: 1.Each variant of model have specific part number for it component. (Example Bumper Myvi Std variant color black/white : XXXXX-XXXXX-AB/C) 2. Booking from customer will be stored in the system and production will start to produce the car based on the order. 3. Ordering of part to all supplier will be generate in the system and the sequence will be follow accordingly. 4. The standard and normal lead time from ordering to deliver the car to customer is about 5 days.
CKD Warehouse
2 Body Shop
Paint Shop
Press Shop
Corporate Building
1.
Supplier
Press
Body
Paint
Assembly
2. 3.
Daihatsu Japan,Indonesia
Supplier
KLB/TLS
Logistic
Assembly
CKD Warehouse
CMK
Assembly
4.
Wheel Assembly
Assembly
5.
Supplier
Assembly
Notes: 1.Perodua start to implement some of the basic concept of TPS from year 2002. 2. At the same time Perodua also implement TPM.
Profit vs Loss Graph (Idea of increase profit through wastage/non value added activity reduction)
PROFIT = SALE PRICE - COST PRICE
Company X Cost Selling price increase Cost Toyota Reduction of cost through TPS
Profit Selling Cost price price up 1 2 1 2 Profit Selling Cost price price reduce
Basic Principle
Heijunka as precondition: 1. Make process as flow 2. Decide tact by necessary volume. 3. Pull out from next process.
1. Using Pull system. 2. Lot size is small. 3. Implement Kanban and Jundate system to save space at line.
1. Running cars is reduced. 2. Accident can be reduced. 3. Missing parts can be less. 4. Lead time to PDI is less. 5. Miss inspect car can be eliminated due to less car.
Body QA PDI
Supplier
Perodua Lg
Paint
Assy Cmk
1. Efficiency of Std Work to eliminate 3 muda. 2. Full Kanban implementation. 3. Minomi supply at lineside. 4. Heijunka production line. 5. Jidoka system to avoid defective vehicles.
1. Less vehicles at distribution yard. 2. Less rework time to be done. 3. Faster delivery to customer due to no holding cars.
Perodua Ordering and Receiving System For Local Part (Year 2004)
DI as reference
PPC Dept.
DI as reference
E-Sims
Vendors
Vendors
Logistics Dept.
Vendors
Hikitori Kanban
Production Line
MILK RUN
Vendors
Vendors
1994
2001 2002 2004
3~5
1~2
days
days
BEFORE
AFTER
Improvement items : 1. Change from carton box to TP (Toyota Polybox). 2. Ordering based on customer ordering (pull system). 3. No need to open and dispose of carton box. 4. TP polybox is returnable. 5. Part easy to see and differentiate. 6. Fifo system had been implemented. 7. Maximum and minimum quantity of part is based on level and quantity at storage area. Visual control. Benefits. 1. Save cost in terms of packaging (recycle and reuse of polybox) ~ Previously carton box. 2. Save operator time to open, count and check part inside the carton box. 3. Better visual control. 4. Reduce cost due to secondary defects such as old stock, wrong part and part missing.
Note : The area of receiving already being calculated to consider : The part size, number of TP polybox should be accordingly with the space provided in order to easy visualize the stock and pre-judge of the stock level with the time. (Normal or abnormal) JIT concept cant be 100% implemented at Perodua due to cost of transport is high and reliability of supplier and Perodua in house to Keep the minimum stock.
Fifo control
Note : 1. Each part have the specific area based on the area that need to supply at the production line. 2. Fifo system implemented using gravity roller stacking part storage from behind and take out from front. 3. Specific parking for buggy car, the parking area specifically tally with the quantity of buggy car. Visual control on buggy car missing or breakdown.
Start Line A1
501
502
503
504
505
506
A1 Line
Trim 1
99 100 101 102 103 104 105 106 107 108 109 110 111 112 113
S/A ENGINE A1 R E P A I R B A Y
S/A CTR A1
JUNDATE A1
HEAVY REPAIR
S/A CTR A3
508
Trim 2
509 146 145 144 141 140 139 138 137 136 135 134 133 132 131 130 129 128
JUNDATE ZONE B
154 153 152 151 150 149 18 147
IP LINE A1
510
End Chassis 1
160 161 162 163 164 165 166 167 168 169 170 174 175 176 177 178
511
Final
179 180 181 182 183 185 186 187 188 189 190 191 192 193
REPAIR BAY A1
512
513
JUNDATE ZONE C
514
SPS FINAL A3
S/A CTR A2
SPS FINAL
SPS DOOR A1
SPS DOOR A2
290 M
REPAIR BAY A2
515
516
Final
336 338 339 340 341 342 343 344 345 346 347 348 349 350 351 352 353 354 355 356 357 358 359
End
517
518
360
519
520
REPAIR BAY
326 325 324 323 316 316 316 316 318 317 316 315 314 313 312 311 310 309 308 307 306 305 304 303 302 301 300 299 298 297 296
Start Line A2
521
S/A ENGINE A2
A2 Line
SPS TRIM S/A GLASS S/A PEDAL
Trim 1
522
523 M
IP LINE A2
SPS TRIM
9 1
Objective : 1. Reduce walking and pick-up time 2. Reduce manpower 3. Improve process arrangement 4. Reduce space
PIC 1
PIC 2
Before
1. 2. Racking Size = 2400 mm No FIFO system
After
1. 2. Racking Size = 800 mm With FIFO system
3.
3.
PIC 1
PIC 2
Before
1. 2. 3. Wire stacked up No FIFO system Double location Supply (LG) & Assy pick-up
After
1. 2. 3. MINOMI style FIFO 5S improvement
4.
KELISA
PIC 1 RR View PIC 2 FR View
Before
1. 2. 3. Big space requirement 2300mm Operator need to dispose empty boxes Operator need to open carton boxes
After
1. 2. Smaller space requirement 1 rack for both Kancil & Kelisa - 1000mm No empty boxes
3.
Before
1. 2. 3. MUDA on walking available 5 seconds No FIFO system Separate racking from main part
After
1. 2. No more walking MUDA on S/Assy rack S/A parts on the same rack as Fuel Pipe
3.
Control Heater
Bracket
Before
1. 2. 3. Difficult to pick-up parts. Operator need to open carton boxes No FIFO system Assy operator need to open packing case
After
1. 2. 3. 4. Operator no need to open carton boxes. Easy pick-up Parts are properly arranged and separated Easy pick-up- Assy operator no more opening packing case With FIFO
Before
1. 2. No FIFO system Quality problems with Weather-strip being dislocated/roll up
After
1. 2. With FIFO Quality up zero DPU in March
2 9 1
PICK UP
KANCIL
WALKING WORKING
KELISA
120
25
140 120 100 80 60 40 20 0
PICK UP WALKING WORKING BEFORE 15 42 64 AFTER 13 20 64 64 64 42 13 20
18 7
14 22 11 13
10
15
66
66
BEFORE 14 22 66
AFTER 11 13 66
21 7.6 8.4 23
34 9.2 24 65 64 79
20 4.6 19 80 87 64
11 4.8 3.8 15
79 101 73
MINOMI AFTER BALANC E SHEET 140 120 100 80 60 40 20 0 WALKING PIC K-UP OPERATION 2 12 7.6 97 3 4 88 4 12 81 5 13 81 6 12 87 7 7 82 8 8.7 87 9 6 78 10 11 12 13 14 14 84 15 4 89 16 18 83 17 18 19 20 12 10 73
OPERATION
PIC K-UP
WALKING
21
22
23 0 0 0
24 10 9.3 91
25 0 0 0
26 12 87
27 19 78
28
29
30 0 0 0
16 9.9 15 77 91 75
17 9.9 17 8.7 71 91
12 7.9 79 79
1ST STEP
2ND STEP
3. JUNDATE SUPPLY
3RD STEP
After Kaizen
1.Fifo 2. Ergonomics
1. FR Exhaust Pipe
3.2 Cost competitiveness for compact car in Asian Region. (Current trends)
Honda Brio 1.2L Launch in Thailand early 2012, Price without tax RM27K and with 70% tax, price is about RM46k.
GM Sail 1.2L Launch in China early 2012, Price without tax RM22K and with 70% tax, price is about RM37k. Note: Current trends: 1.Many new player focusing on compact car segment. 2. Thailand and China supplier strong in the cost competitiveness due to volume, competitive labor cost, technical capability due to most supplier are Japanese joint venture and compare to Malaysia majority Supplier were technical assistance support.
3.3 High technology in producing (automation) new concept of automotive ~hybrid/electrical engine, new environmental friendly system-less emission, high safety factor, module system (Future trends)
Interior
Paint
Customer
Note: Future trends : Highly automation and production efficiency is very high and the automotive technology also change towards enviromental friendly, safety and energy saving. High in automation cost (fix cost) but efficient to produce high volume.
4.0 Recommendation.
5.0 Conclusion.
5.0 Conclusion.
1. In order to survive in global and liberalism market, Perodua need to enhance automotive technology (hybrid, electrical) and production automation capability. 2. Without compliance with the enviromental, safety, emission new regulation and competitive in cost, it is difficult for Perodua to export to oversea. 3. The government should encourage the national automotive industries in research and development activity so that they can sustain in the industries after.
Thank You