Page 2 Contents OYLM COMPANY PROFILE & ORGANISATION CHART
FACTORY FACILITIES OYLM PRODUCTIVITY & PROCESS IMPROVEMENT OYLM
QUALITY IMPROVEMENT HUMAN RESOURCE DEVELOPMENT SAFETY, HEALTH &
ENVIRONMENTAL ACTIVITIES
Slide 3
Page 3 OYLM Company Profile Company NameO.Y.L. Manufacturing
Company Sdn Bhd FounderTun Omar Ong Yoke Lin (OYL) LocationLot
60334, Persiaran Bukit Rahman Putra 3, Taman Perindustrian Bukit
Rahman Putra, 47000 Sungai Buloh, Selangor Darul Ehsan. Date
Incorporated7 th February 1974 Core BusinessAir Conditioner
Manufacturer Paid Up CapitalRM276 Million (2008) ShareholderDaikin
Industries Ltd Land Area115,214 m 2 Factory Area91,440 m 2
Production Line11 production lines SalesRM980 Million (2008)
Production Quantity1.308 Million units (2008) Total Headcount1,491
person (Apr 2009)
Slide 4
Page 4 Hitoshi Jinno Chief Operating Officer G. Procurement
(Asia) Khor Leong Huat Manager Hirokazu Hirao General Manager
Global UP S&D Sum Chee Chong Operating Manager Global UP PM Lim
Soon Kiong Operating Manager Factory Management Tan Yong Cheem
Operating Manager Human Resources Ang Chong Kwoi Manager Finance
Raghaven Muniyandi Manager MIS Loh Cheng Hong Manager Corp. Mfg.
Planning Yutaka Hoshino Manager Global Procurement Ho Much Jia
Manager Prod. Engineering Yim Tuck Wah Manager QAQC Tan Yock Fat
Manager Factory 2 Goh Kwee Cheng Manager Factory 1 Liew Kim Mon
Manager Material Control Chan Yew Lee Manager OYLM Organization
Chart
Slide 5
Page 5 OYLM Headcount *Note : Contract workers (134 males and
15 females) are excluded from above statistic Information shown as
at April 2009.
Slide 6
Page 6 Factory Comparison Before Centralized Manufacturing
Plant Entrance We Are Here Main Plant (Sec 15, Shah Alam) Main
Plant (Sec 15, Shah Alam) Line E (Sec 16, Shah Alam) Line E (Sec
16, Shah Alam) Line CE (Banting) Line CE (Banting) Warehouse
(Sungai Buloh) Warehouse (Sungai Buloh) OYLM R&D (Sungai Buloh)
OYLM R&D (Sungai Buloh) Main Factory Satellites Present
Slide 7
Page 7 Factory Facilities Product Gallery Mezz Floor Training
RoomU-Bend Assembly CE Assembly E2 Assembly E1 Assembly B1 Assembly
B2 Offices Material Control Preparation Area Viewing Gallery Rest
Area Fan Division Material Control Mock Up Area Preparation Area CK
Panel Wiring
Slide 8
Page 8 Factory Facilities Ground Floor Material Control Paint
Shop Stamping Line Offices Maintenance IE Workshop Metal Line
Piping Shop Piping Shop Insulation Area Coil Line CE Coil Line E2
Coil Line E1 Coil Line B1 Coil Line B2 Assy CE Assy E2 Assy E1 Assy
B1 Assy B2 Offices Canteen Offices Lobby Rest Area Coil Line F Coil
Line C Coil Line A Coil Line D Coil Line G & H Assembly F
Assembly C Assembly A Assembly D Assembly H Assembly G
Slide 9
Page 9 Factory Capacity LineProduct Range Refrigerant Type
Design Capacity Design Capacity ( Yr) 2009 Actual Output ( Yr)
Loading Residential Assembly B1 Single Split (0.75HP to 3HP)Outdoor
UnitR22, R410A339,300 169,650127,994 75.45% Assembly B2 Multi &
Single split (2-6 HP)Outdoor UnitR22, R410A156,600 78,30045,191
57.72% Assembly E1 Wall Mounted (0.7 to 3 HP)Indoor UnitN/A287,100
143,55091,606 63.81% Assembly E2 Wall mounted (1 to 3 HP)Indoor
UnitN/A261,000 130,50085,901 65.82% Sub Total
1,044,000522,000350,692 67.18% Light Commercial Assembly C Single
split (3-6 hp) Water Source (1-6HP) Outdoor UnitR22, R407C,
R410A117,450 58,72537,926 64.58% Assembly CE Ceiling Expose (3-6
hp) Ceiling Conceal Indoor UnitN/A78,300 39,15023,932 61.13%
Assembly F Ceiling Cassette Ceiling Expose E Indoor UnitN/A99,180
49,59037,007 74.63% Sub Total 294,930147,46598,865 67.04%
Commercial Assembly A Outdoor/Indoor 5HP to 12HP Outdoor &
Indoor unit R22, R407C20,880 10,4406,803 65.16% Assembly D
Outdoor/Indoor 15HP to 35HP Rooftop 5HP to 12HP Outdoor &
Indoor unit R22, R407C10,440 5,2202,262 43.33% Assembly H Rooftop
15HP to 47HP Indoor 40HP to 75HP Outdoor & Indoor unit R22,
R407C,4,176 2,0881,559 74.66% Sub Total 35,49617,74810,624 59.86%
Overall Total 1,374,426687,213460,181 66.96%
Slide 10
Page 10 Line BalancingKanban System Training PDS Basic Process
Improvement Activities 1 5S Training Acquired Production Daikin
System (PDS) knowledge
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Page 11 Before All parts are at the side of the assembly line
The quantity of parts for each pallets is different Current All
parts are consolidate in one area Picking by set Missing parts can
be identified Correct parts are used Process Improvement Activities
2 Kitting & Picking System Assembly Line Material
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Page 12 Process Improvement Activities 2 Kitting & Picking
System Residential IndoorResidential OutdoorCeiling Exposed
IndoorLight Commercial Outdoor Accessories PickingBase Pan
PickingBlower KittingBase Pan Picking Ceiling Cassette PanelCeiling
CassetteCommercial OutdoorPackage Unit Parts Kitting Metal Parts
PickingPiping Picking
Slide 13
Page 13 Quality Improvement 1 Acquired Japan Most Advanced Air
Cond. Manufacturer Technology Inverter Testing Module (Indoor
Unit)Inverter Testing Module (Outdoor Unit) Indoor inverter testing
ready Single split inverter testing ready Multi split inverter
testing ready *Included data logging
Slide 14
Page 14 Air Tight Testing Pressure No operator is allowed
inside the safety fence while air tight test in progress for safety
purpose. Quality Improvement 2 Commercial Unit Air Tight Test
fulfill PED Standard RefrigerantCoil LineAssembly Line
R223.29Mpa1.55Mpa R407c3.29Mpa1.78Mpa R410a4.19Mpa2.51Mpa
Slide 15
Page 15 Quality Improvement 3 Packing Watch Dog Be sure before
we ship High Side Label Carton Label Unit Label Residential Indoor
Residential Outdoor
Slide 16
Page 16 Supplier request Part measures outside position (14.0)
is not clear. Request to unite outside(14.0) tolerance with process
capacity 23 14.0 +0.075 -0.100 Revise contents Angle from central
line to outside measurement part is added. Hundreds of parts are
measured by cooperation with supplier, product evaluation is
performed and tolerance is determined Production, QC request
Improvement of fan vibration Each size of boss parts is not
indicated Request to put in full length tolerance Revise contents
Append to detailed drawing & tolerance Hundreds of parts are
measured by cooperation with supplier, product evaluation is
performed and tolerance is determined. Indoor fan bearing (OYL
drawing) Plastic fan (supplier drawing) 15.0 +0.06 -0.0 43.0 200
+0.0 Quality Improvement 4 Drawing Revised Example
Slide 17
Page 17 OYLM Productivity Improvement Increase of local sales
Economics Crisis Domestic Sales Recovery
Slide 18
Page 18 Descriptions200720082009 Market Defect Ratio (All
Products)1.99%1.30%1.21% Market Defect (Products in 2009) -- 0.27%
Market Defect (New Products) -- 0.18% Quality Improvement
Page 20 Descriptions200720082009 Purchased Parts Defect
Ratio0.37%0.33%0.23% FTA Analysis-6 times60 times Quality
Improvement
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Page 21 Market Defect Ratio Target 09 < 1.10%
Slide 22
Page 22 Manufacturing Defect Ratio
Slide 23
Page 23 HR Development (HRD) New Operator Training Program
Evaluation Termination To Line 1 st Day Walk Test Run Test Stick
Test Cards Test 1 st Day Orientation Company Background Rules &
Regulation & Test Safety & Health Awareness & Test 2 nd
Day Basic of Air Conditioner & Test Environmental Awareness
& Test OYLM Product 5S Housekeeping & Test Motivation 1 st
Day Product Quality RoHS Compliance Accident Case Dangerous
Materials Basic of Screw Driving & Test 2 nd Day Indoor Split
Assembly & Test 3 rd Day Outdoor Split Assembly & Test Pre
Orientation Test (1 Day) Orientation Program (2 Days) Skill Shop
Training (3 Days) Pass Not Pass Pass
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Page 24 HRD New Operator Training Pre Orientation Test (1 Day)
Orientation Program (2 Days) Skill Shop Training (3 Days) New
Operator Training Program Walk Test Stick Test & Card Test
Safety & Health Awareness Orientation Screw Test Outdoor
Assembly Test
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Page 25 HRD Special Skill Training Special Skill Training
Program Brazing Training Forklift Training Wiring Training Required
Nomination
Slide 26
Page 26 HRD Safety Training Operator Safety Training Program
Importance of E-Stop 24V Electrical Shock Pneumatic Pressure Test
Chain Drive Pinching Force Safety Training Table
Slide 27
Page 27 HRD Daikin Skill Pre-Olympic Title : Daikin Asia
Oceania Skill Pre-Olympic Competition 2009 Venue : Thailand 4 th
Mr. Norhafiz
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Page 28 Safety & Health Policy
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Page 29 Safety & Health Activities
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Page 30 Safety & Health Activities
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Page 31 Safety & Health Activities
Slide 32
Page 32 Safety & Health Week PPE WEEK To educate employees
on selection, usage and maintenance of PPE FORKLIFT COMPETITION
Enhance skills and knowledge in driving forklift. Promote safety
driving through healthy competition. HEALTH WEEK Increase health
awareness by providing health screenings, activities &
exhibitions. SAFETY & HEALTH MONTH
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Page 33 3C4R Environmental Policy
Slide 34
Page 34 Environmental Activities Main Station Factory 2
Satellite Station Factory 1
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Page 35 Environmental Activities
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Page 36 Environmental Activities
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Page 37 Environmental Activities
Slide 38
Page 38 Corporate Social Responsibility Activities
