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AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

DEVELOPING & SUSTAINING LEAN FOR AMM NEW BUIDING

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Action 1A - Floor Marking Work Area Floor Marking Work Area ~ OSHA Floor Marking Standard

00 0 O" 00 O L OOC 00

Ground Floor

First Floor

AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

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Action 1A : Visual Work Area (ESS Area) Floor Marking Work Area ~ Assembly Bay A (Ground Floor)

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After

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Assembly Bay A # with 5 Sub Bay

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AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

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Action 1A: Visual Work Area (ESS Area) Floor Marking Work Area ~ Assembly Bay B (Ground Floor)

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After

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Assembly Bay B # with 7 Sub Bay

AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

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Action 1A : Visual Work Area (ESS Area) Floor Marking Work Area ~ Assembly Bay C (Ground Floor)

Before

After

Assembly Bay C # with 7 Sub Bay

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AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

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WIRE ARNESS EMPTY SPACE l)üüR EMPTY SPACE NC LAYOUT p ART IT ION p ART IT GLASS SUB STORE SERVER TRAY ULE ASS MODULE ASS EME Y

Action 1A : Visual Work Area (ESS Area) Floor Marking Work Area ~ Harnessing Workstation Bay (1 st Floor)

Before

After

Harnessing Workstation Bay

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AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

Scene 7 (1m 40s)

WIRE ARNESS NC LAYOUT p ART IT ION EMPTY SPACE l)üüR EMPTY SPACE GLASS SUB STORE SERVER TRAY ULE ASS MODULE ASS EME Y

Action 1A : Visual Work Area (ESS Area) Floor Marking Work Area ~ Sub Assembly Area (1 st Floor)

Before

After

Harnessing Workstation Bay

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AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

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WIRE ARNESS EMPTY SPACE l)üüR EMPTY SPACE NC LAYOUT p ART IT ION p ART IT GLASS SUB STORE SERVER TRAY ULE ASS MODULE ASS EME Y

Action 1A : Visual Work Area (ESS Area) Floor Marking Work Area ~ Assembly Work Area Room A (1 st Floor)

Before

After

1. Tray Assy 2. Tray Functional Test & Calibration

AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

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Tray Functional Test & Calibration

Tray Workstation Bay

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WIRE ARNESS NC LAYOUT p ART IT ION EMPTY SPACE l)üüR EMPTY SPACE GLASS SUB STORE SERVER TRAY ULE ASS MODULE ASS EME Y

Action 1A : Visual Work Area (ESS Area) Floor Marking Work Area ~ Assembly Work Area Room B (1 st Floor)

1. Packing Workstation Bay 2. Kit Workstation Bay 3. Torque Check Calibration Workstation Bay 4. Laser Workstation Bay 5. Supervisor Bay

AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

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AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

Action 1A : Visual Work Area (ESS Area) CONT… Floor Marking Work Area ~ Assembly Work Area Room B (1 st Floor)

After

Before

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Packing Workstation

Laser Workstation

Supervisor Bay

Kit Workstation

Torque Wrench Calibration Workstation

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Action 1 (B1) - “Visual Display” Good Segregation & Identification (Labelling & Visualization card)

WORKSTATION

HARNESSING INCOMING MATERIAL

LCOLUMN MODULE WORKSTATION

WORKSTATIOfBAY

ROBOT WORKStÅTlON

a) Harnessing Work Area Plan – 1 st Floor

AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

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Action 1 (B1) – “Visual Display” Good Segregation & Identification (Labelling & Visualization card)

a) Harnessing Work Area Actual

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FACILITY MODULE WORKSTATION BAY

COLUMN MODULE WORKSTATION BAY

ROBOT MODULE WORKSTATION BAY

I/O MODUE WORKSTATION BAY

QC INSPECTION WORKSTATION BAY

HARNESSING INCOMING MATERIAL WORKSTATION BAY

AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

Scene 13 (3m 51s)

Action 1 (B1) - “Visual Display” Good Segregation & Identification (Labelling & Visualization card)

b) Assembly Work Area Room “A” Actual – 1 st Floor

TRAY ASSEMBLY “B” WORKSTATION BAY

TRAY ASSEMBLY “A” WORKSTATION BAY

TRAY FUNCTIONAL TEST & CALIBRATION WORKSTATION BAY

AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

Scene 14 (4m 10s)

Action 1 (B1) - “Visual Display” Good Segregation & Identification (Labelling & Visualization card)

c) Assembly Work Area Room “B” Actual – 1 st Floor

TORQUE CHECK CALIBRATION WORKSTATION BAY

LASER WORKSTATION BAY

AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

KIT WORKSTATION BAY

PACKING WORKSTATION BAY

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Action 1 (B1) - “Visual Display” Good Segregation & Identification (Labelling & Visualization card)

d) Assembly Work Area – Ground Floor

AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

SUB.ASSEMBLY WORKSTATION 2

ASSEMBLY BAY A

MATERIAL AREA

ASSFMBLY BAY D

ASSEMBLY

PARKING

STACKER PARKING

PARKING

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Action 1 (B1) - “Visual Display” Good Segregation & Identification (Labelling & Visualization card)

d) Assembly Workstation Bay – Ground Floor

AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

ASSEMBLY BAY B

abstract

abstract

ASSEMBLY BAY C

ASSEMBLY BAY A

Continue in next slide…

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SUB WORKSTATION TROLLEY SIGNAGE BAY

Action 1 (B1) - “Visual Display” Good Segregation & Identification (Labelling & Visualization card)

Sub Workstation Trolley Signage Bay Explaination

AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

1. I/O CHECKLIST FORM 2. PRE-OQA CHECKLIS FORM 3. DE-INSTALLATION CHECKLIST FORM

TOOL SERIAL NUMBER AEM TOOL NUMBER SUB BAY AREA MAIN ASSEMBLY BAY SHIPMENT SITE & MINI DYSC VOLTAGE FOR SHIPMENT

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Action 1 (B1) - “Visual Display” Good Segregation & Identification (Labelling & Visualization card)

e) Transportation Work Area – Ground Floor

AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

STACKER PARKING FORKLIFT PARKING PALLET JACK PARKING

PALLET JACK

STACKER

FORKLIFT

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Action 1 (B2) – “Visual Display” Safety & Health Workplace Activity

Objective: To ensure and promote a safe work environment for employees

Responsibility: One of the most important responsibilities employers have to their employees is to provide safe workplaces including its requirements for employers and the manner in which the law is enforced.

Why Safety Sign Important: visual communication of key safety messages Highlighting safe methods of work as well as hazards Legal requirements Better safety benefits everyone

WORK SAFELY!

To Better Communicate Workplace Hazards

AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

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Action 1 (B2) – “Visual Display” Safety & Health Workplace Activity

a) Example Safety Sign - Safety Sign OSHA Standard

DANGER KEEP OFF! Hazardous voltage above. Will cause severe injury or death.

Will result in death or serious injury

Could result in death or serious injury

Could result in minor or moderate injury

Safety procedures and similar labels and sign

Safety procedures and similar labels and sign

AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

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Action 1 (B2) – “Visual Display” Safety & Health Workplace Activity

iv) Notice Sign - Safety Sign OSHA Standard

AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

Safety procedures and similar labels and sign

ASSEMBLY WORK AREA ROOM B NOTICE DO NOT ENTER AUTHORIZED PERSONNEL ONLY

ASSEMBLY WORK AREA ROOM A NOTICE DO NOT ENTER AUTHORIZED PERSONNEL ONLY

In Progress

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Action 1C – “Visual Scheduling”

Manufacturing Assembly Control Boards

AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

i. Wire Harness Performance vs Completion Target

I/O MODULE ROBOT MODULE COLUMN MODULE FACILITY MODULE

Purpose of Visual?

sage platf

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Action 1C – “Visual Scheduling”

Manufacturing Assembly Control Boards

AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

iii. Production Schedule vs Builds Completion

ASS' MODEL TOOL SCHEDULE STATUS .0EL BUILD 10 MR OQA SHIP REMARKS cou_'MN

Visual Scheduling telling about?

• The display of goals, target etc., so everyone knows what has to be done and progress in achieving it

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Action 1C – “Visual Scheduling”

Manufacturing Assembly Control Boards

AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

ii. Material Shortage Boards vs Plan

REMARK' 20 / SS gooz9-HBooB

Next Target LM for Visual Scheduling

Arts in Designing & Developing Attractive Straight to the point message

A,4nrah! J 89

Example

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Action 2 (i) – Good Manufacturing Practices (GMP) GMP ~ 7 Aspects

AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

PERSONAL ERSONAI o HOUSE- CONT L KEEPING

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Action 2 (i) – Good Manufacturing Practices (GMP) GMP ~ (1: Safety Briefing)

AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

SAFETY AND HEALTH – WHY?

Mandatory under the law. It is one of the general duties as prescribed under the Occupational Safety and Health Act 1994 (Act 514) for the employer to provide a safe workplaces to their employees and other related person. ……. OSH ACT

OSHA 1994 Requirement For all industries If >5 Employees -Safety & Health Policy ≥40 Employees (S30) -Safety & Health Policy + Safety & Health Committee For high risk industries (i.e. construction, ship building, gas etc.) >100 Employees -Safety & Health Policy + Safety & (Order 1997) Health Committee + a Certified Safety & Health Officer For low risk industries (other than the above mentioned industries) >500 Employees -Safety & Health Policy + Safety & (Order 1997) Health Committee + a Certified Safety & Health Officer

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Action 2 (i) – Good Manufacturing Practices (GMP) Industry Statistics Fatality & Accidents in Work Place

AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

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Action 2 (i) – Good Manufacturing Practices (GMP) Basic Safety Rule Briefing

AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

Never do anything that is unsafe in order to get the job done. .

Never operate a piece of equipment unless have been trained and are authorized.

Working under the influence of alcohol or illegal drugs or using them at work is prohibited.

Loose clothing, jewellery and hair longer than shoulder length shall not be worn around moving machinery

Use your personal protective equipment whenever it is required. .

Obey all safety warning signs.

Do not bring firearms or explosives onto company property.

Smoking is only permitted outside the building away from any entry or ventilation intake..(Smoking area is provided)

Horseplay, running and fighting are prohibited

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AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

Long Hair Prohibited

Must wear suitable clean clothing and enclosed footwear (Safety Shoes)

Short Pant is not allowed

Excessive Perfume Prohibited

Fingernails must be clean and nail polish are prohibited!

Do not carry object or tools in unbuttoned or unzipped clothes

No open-toed or high heels

Personal item should be put away

Action 2 (ii) – Good Manufacturing Practices (GMP) GMP ~ ( 2: Personal Attire )

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SAFE DISEASE SANITATION OCIM-R 15 NAILS PERSONAL PREVENTION SOAP CONTROL HEALTH PETS TOUCHING FREQUENT HANDLING pUBLlC CLEANING DIRTY BACTERIA PEOPLE MICROBES ANTISEPTIC CARE DISPENSER HANDSOAP METHODS RINSE SOAP hNaOH PRESERVATION CHEMICAL TOWEL STAY HEALTHY! WIPES ANTIOXIDANT FAUCET CELS FOAM CLEANER PALM CHEMICAL HYGIENE FINCERS5RUB AIR DRY ALCOHOL PREVENT AFTER TOILET FOAM DANGER ucoa BASED LATHER WARNING HANDWASHING RIJCEOJRE SANITIZERS RUNNING WATER HEALTHTOILETSNEEZEGERMS„ —-{DESTROY EFFECTIVE INFECTIONS LEARN— BACTERIUM IN*OIENTS WASHZ HANDS DISEASE — LATHER a—WASTE DANCER IMPORTANT- DISINFECT VIRUS —SAVE SANITIZERFWAfER* ANTIBACTERIAL SODIUM

Action 2 (iii) – Good Manufacturing Practices (GMP) GMP ~ ( 3: Hygiene & Health )

AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

All employees are to observe & maintain proper hygiene when using the washing facilities & common toilet. Toilet bowls & urinal port shall be flushed after each use.

All hands have to be thoroughly washed & cleaned after handling chemical and solvent before consuming any food.

If splashed with acid or other corrosive chemical, wash freely with water and seek for first aid.

Wear gloves to protect hands against cuts and burns.

All wound need to be coverd

Always come to work healthy

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Action 2 (iv) – Good Manufacturing Practices (GMP) GMP ~ ( 4: Personal Item & Jewellery )

AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

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Locker for AEM Staff

Locker for ELTRIO Staff

Personal items should be put away

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AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

Action 2 (v) – Good Manufacturing Practices (GMP) GMP ~ ( 5: Food Allergen Control )

Make sure the pantry is neat and tidy. The bottles and food should be arranged in the place provided. Inedible foods should be discarded

Wash hands: After using the restroom After eating or drinking After handling waste or raw food After sneezing or coughing At least 20 seconds

Eat / Drink in designated area only

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AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

Please ensure that cigarette butts are places in the provided containers!

Smoking of cigarettes, vaporizers & tobacco in all areas of the premise is strictly prohibited except at designated smoking area.

Social Distancing : Only 6 people are allowed per time

Action 2 (vi) – Good Manufacturing Practices (GMP) GMP ~ ( 6: Smoking )

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AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

All unwanted items should be disposed off in proper containers and bins. There shall be no littering in the Company's premise.

All employees shall keep their workplace clean & tidy. This is to eliminate the possibility of an accident occurring due to the untidy & messy workplace.

Be a practitioner of good housekeeping. Keep all tools and surroundings clean and all equipment in their proper place.

Action 2 (vii) – Good Manufacturing Practices (GMP) GMP ~ ( 7: Housekeeping )

All spillages on surfaces shall be cleaned immediately to prevent slips, trips and falls whilst working.

No one shall obstruct or cause obstruction along designated passageways, fire protection equipment and fire exits at all times.

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AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

Action 2 (viii) – Good Manufacturing Practices (GMP) ( IN-HOUSE SAFETY RULES & REGULATION FOR EMPLOYEES - “EP 4.4.6-03B ) - Briefing

1. Use of Personal Protective Equipment (PPE)

2. No Smoking / Horseplay

3. Obeying Safety Instructions

4. Personal Hygiene & Health

5. Obtain Relevant Permit

6. Safe Practices

8. Housekeeping

9. Equipment & Tools

10. Penalty & Violations

7. Hazard/Incident Report

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Action 3(a) – Waste (MUDA) Management Activity Waste Category - Process Flow

AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

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Action 3(a) – Waste (MUDA) Management Activity – [a. Waste Category] i) Disposable Waste – Waste Disposition Area

AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

Disposable

Disposable

Disposable EM

Otsposable

Ground Floor

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Action 3 – Waste (MUDA) Management Activity – [a. Waste Category] ii) Recycle Waste – Paper, Plastic, Rag Oil

AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

Ground Floor

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Paper

Plastic

Rag Oil

Rag Oil

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WIRE ARNESS EMPTY SPACE l)üüR EMPTY SPACE NC LAYOUT p ART IT ION p ART IT GLASS SUB STORE SERVER TRAY ULE ASS MODULE ASS EME Y

Action 3 – Waste (MUDA) Management Activity – [a. Waste Category] ii) Recycle Waste – Paper, Plastic, Rag Oil

AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

1 st Floor Floor

Paper

Plastic

Rag Oil

Scene 40 (13m 50s)

Action 3 – Waste (MUDA) Management Activity – [b. Waste Inventory] i) Fastener Inventory - Screw/Nut/Dowel Pin/Washer

AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

DOWEL PIN

In Progress (80%)

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BH SCREW

CS SCREW

CAP SCREW

CAP SCREW

CAP SCREW

CAP SCREW

Before

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Action 4 – AMM Vitality i) Morning Exercise - Introduce Fun Activities at Work to Improve Employees Health

AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

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AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

Action 4 – AMM Vitality ii) Health Program - A health program that rewards healthy choices.

UNDER PROPOSAL-COMING SOON

KNOW YOUR HEALTH IMPROVE YOUR HEALTH ENJOY THE REWARDS

This program constitutes a proposal to purchase a Smart Body Composition Scale. The propose of purchasing is to measure health condition our staffs for ESS vitality Program.-The staffs are scaled before and after program by using Smart body composition scale.-The result is measured in every weeks for 3 months.-This activity is not only for maintain our staffs' health but also to implement ISO9001:2015 clause 5.1.1 (i) & 7.1.4 (b)

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AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

Action 5 – Energy Saving Program i) Air Conditioner – 1 ST Floor (Assembly Work Area Only)

Switch off the air-conditional 10 minutes before end of working hour 1 Day = 10 Min = 0.166667 Hr 1 Week = 10 Min x 5 Day = 50 Min = 0.833333 Hr 1 Month = 50 Min x 4 Week = 200 Min / Month = 3.33333 Hr 1 Year = 200 Min x 12 Month = 2400 Min = 40 Hr

d) Saving Cost for 1 Year: = 1.492KW x 40 Hr x RM0.218 = RM13.01 x 40 Month = RM520.41

a) Saving Rate per 1 Day: = 1.492KW x 0.166667 Hr x RM0.218 = RM0.0542 x 40 Unit = RM2.168

b) Saving Rate per 1 Week: = 1.492KW x 0.833333 Hr x RM0.218 = RM0.271 x 40 Unit = RM10.84

c) Saving Rate per 1 Month: = 1.492KW x 3.33333 Hr x RM0.218 = RM1.084 x 40 Unit = RM43.37

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AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

Action 5 – Energy Saving Program ii) Air Conditioner – 1 ST Floor (Assembly Room B)

Switch off 1 from 3 air-conditional during working hour

1 Week (41.25 Hr) = 1.492KW x 41.25 Hr x RM0.218 = RM13.42

1 Month (165 Hr) = 1.492KW x 165 Hr x RM0.218 = RM53.67

1 Year (1980 Hr) = 1.492KW x 1980 Hr x RM0.218 = RM644.00

Switch off 2 from 10 air-conditional during working hour

1 Week (41.25 Hr) = 1.492KW x 41.25 Hr x RM0.218 = RM13.42 x 2 Unit = RM26.84

1 Month (165 Hr) = 1.492KW x 165 Hr x RM0.218 = RM53.67 x 2 Unit = RM107.34

1 Year (1980 Hr) = 1.492KW x 1980 Hr x RM0.218 = RM644.00 x 2 Unit = RM1288.00

iii) Air Conditioner – 1 ST Floor (Wire Harness Work Area)

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AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

Action 5 – Energy Saving Program iv) Purpose

Energy Saving Program iv) Theoretical Result for Air Conditional 1 st Floor (Total Assembly Work Area) 1 st Floor (Assembly Room A) 1 st Floor (Wire Harness Work Area)

“Improve Quality”

“Reduce Lead Time”

“Reduce Cost ”

Better

Faster

Saving

Next Agenda

Next Agenda

In Progress Planning

Total Cost Saving For 1 month: = RM43.37 + RM53.67 + RM107.34 = RM204.38

Total Cost Saving For 1 Year : = RM520.41 + RM644.00 + RM1288.00 = RM2452.41

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World Class Concept – We need to be able to do three things well, all the same time

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AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

Action 6 – 5S SUSTAIN a) Audit Score Check List Cards

5S programs maintain their effectiveness when each workstation is occasionally assessed to make sure workers are abiding by 5S principles. This audit check list card will allow to quickly and effectively spot-check (Audit) each work area to fulfill 5S’s fifth principle: Sustain.

Work Culture Result by Area – IN PROGRSS

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N ext Focus : a) Completing Visual Management

AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

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N ext Focus : b) Completing Good Manufacturing Practices - Pending Briefing

AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

N ext Focus : c) Waste Management Activity

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AMM Lean KPI - Year 2021

AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

Principle Objective Initiatives Target Value To support company profitability • Cost saving • Kaizen projects • 8k in 2021 • 8 projects in 2021 Lean To increase lean awareness among employees • My kaizen • Lean news • Lean Quiz • 5S competition • 1 ideas /employee • 3 x yearly • 1 x yearly • 1 x yearly

“A long journey that needs commitment, patience, long-term thinking, positive mindset and attitude, and continuous improvement which are merged together as operational excellence and as a strategic weapon.”

It’s not easy……

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Quote :

AMM Overall Schedule for Lean Manufacturing Implementation in New Plant

“Many good companies try to practice kaizen and use various TPS tools. But what is important is having all the elements together as a system. It must be practiced every day in a very consistent manner ‐ not in spurts ‐ in concrete way on the shop floor.” ‐Fujio Cho, Chair of the Board, Toyota

Lean is a way of thinking – it is a mindset and not just a program focused on cost-cutting