UMW Toyota organize plant tour for media
The doors to the Assembly Services Sdn Bhd (ASSB) plant, which has been rolling out Toyota vehicles since 1968, were opened to members of the media yesterday, as UMW Toyota Motor held a press visit to the facility with the aim of reinforcing the company’s message that it remains committed to deliver quality Toyota vehicles to its customers.
Currently, the plant produces vehicles for consumption in the Malaysian market; its lineup consisting of the Vios, Fortuner, Hilux, Innova, Hiace, and lorries for Daihatsu and Hino. A total of RM290 million has been poured into the ASSB plant’s facilities over the past five years, and a further RM170 million is set to be spent over the next three. The Avanza is also manufactured locally, but at Perodua’s plant in Rawang.
In addition to investments on the factory, UMWT will be shelling out a further RM200 million for an all-new centralized stockyard in Bukit Raja which would also accommodate an accessories centre, test track, and body & paint centre. Scheduled for operation by mid-2011, the yard allows UMWT to keep its stocks under a shaded premises and minimize periods that undelivered cars spend under the baking sun.
“Following the spirit of Kaizen – Continuous Improvement, we are constantly improving our quality standards and we will raise the quality bar. We will continue to ensure that the high quality aspects are adhered to, and it is extended beyond the assembly plant to our business partners, such as our suppliers and authorized dealers,” said Mr Kuah Kock Heng, President of UMW Toyota Motor Sdn Bhd.
Mr Kuah himself, alongside Deputy Chairman Mr Takashi Hibi, and ASSB Plant Director Hideki Omae were present to accompany the media as we were shown around the plant’s various facilities. Plants operations are split to four distinct lines – one for the Vios; one for the IMV platform, which consists of the Hilux, Fortuner and Innova; one for the Hiace van; and the remaining line for Daihatsu and Hino lorries.
Like in any well-managed plant, the emphasis on safety was clear, as we were instructed to come in long-sleeve shirt, long pants and shoes. Helmets and visibility vests were provided, and visitors without spectacles were required to wear protective goggles. What immediately impressed was that at each work station we stopped at, the staff responsible for presenting to us the role of his team in the process would start off his speech by making a verbal declaration of their pledge towards plant safety – without fail.
We moved around the plant walking strictly within designated walkways. If a forklift or any moving vehicle was traveling nearby, it would stop. After we leave a clear path for it to move, it would honk to indicate movement. Another practice, which many of us admittedly did not adopt, was the use of hand signals to indicate direction of movement – pointing at the direction which one is going.
The plant’s process flow heavily integrates the renowned Toyota Production System to ensure that each car that rolls out is of the same faultless quality which Toyota cars are renowned for. It is not the most advanced of automotive plants, but it is certainly well-organized and well-oiled. In the event that a defect of any kind is detected, either by man or machine, the entire production line stops and only resumes after the relevant errors are corrected.
Supplying this plant are some 65 local vendors, the highest number amongst non-local car makes. The Toyota Vios is built with a total of 40% local content, and UMW plans to raise that figure to 50% with the next generation model. As a parting shot before we dispersed, it was also announced during the plant tour that the next generation Toyota Camry will be assembled CKD in Malaysia by 2012.
According to an official statement sent as a follow up from our visit, the initial investment would set UMWT back by RM100 million. Local content is not likely to exceed 20% at the start of the CKD project, but plans are in place to gradually increase that figure with vendor development programmes to help increase supplier expertise in working with the considerably more complex Camry.
