Page 1
Liew Kim Mon
Factory Manager
Production Department
Contents
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Page 2
OYLM COMPANY PROFILE & ORGANISATION CHART
FACTORY FACILITIES
OYLM PRODUCTIVITY & PROCESS IMPROVEMENT
OYLM QUALITY IMPROVEMENT
HUMAN RESOURCE DEVELOPMENT
SAFETY, HEALTH & ENVIRONMENTAL ACTIVITIES
OYLM Company Profile
Company Name
O.Y.L. Manufacturing Company Sdn Bhd
Founder
Tun Omar Ong Yoke Lin (OYL)
Location
Lot 60334, Persiaran Bukit Rahman Putra 3,
Taman Perindustrian Bukit Rahman Putra,
47000 Sungai Buloh,
Selangor Darul Ehsan.
Date Incorporated
7th February 1974
Core Business
Air Conditioner Manufacturer
Paid Up Capital
RM276 Million (2008)
Shareholder
Daikin Industries Ltd
Land Area
115,214 m2
Factory Area
91,440 m2
Production Line
11 production lines
Sales
RM980 Million (2008)
Production Quantity
1.308 Million units (2008)
Total Headcount
1,491 person (Apr 2009)
Page 3
OYLM Organization Chart
Hitoshi Jinno
Chief Operating Officer
Hirokazu Hirao
General Manager
Factory Management
Tan Yong Cheem
Global UP PM
Lim Soon Kiong
Global UP S&D
Sum Chee Chong
G. Procurement (Asia)
Khor Leong Huat
Operating Manager
Operating Manager
Operating Manager
Manager
Page 4
Human Resources
Ang Chong Kwoi
Finance
Raghaven Muniyandi
Global Procurement
Ho Much Jia
MIS
Loh Cheng Hong
Corp. Mfg. Planning
Yutaka Hoshino
Manager
Manager
Manager
Manager
Manager
Prod. Engineering
Yim Tuck Wah
Material Control
Chan Yew Lee
QAQC
Tan Yock Fat
Factory 1
Liew Kim Mon
Factory 2
Goh Kwee Cheng
Manager
Manager
Manager
Manager
Manager
Factory Comparison
Before
Satellites
Main Factory
Main Plant
(Sec 15, Shah Alam)
Line E
(Sec 16, Shah Alam)
Warehouse
(Sungai Buloh)
Line CE
(Banting)
OYLM R&D
(Sungai Buloh)
Present
Centralized
Manufacturing
Plant
We Are Here
Page 6
Entrance
Factory Facilities
Mezz
Floor
U-Bend
Training Room
Viewing Gallery
Assembly CE
Assembly E2
Assembly E1
Preparation
Area
Assembly B1
Offices
Offices
Offices
Offices
Viewing Gallery
Product Gallery
Assembly B2
Rest Area
Page 7
Material
Control
Fan
Division
Material Control
CK
Panel
Wiring
Preparation Area
Mock Up
Area
Factory Facilities
Ground
Floor
Piping Shop
Paint Shop
Stamping Line
Maintenance
Coil Line CE
Assy CE
Coil Line E2
Assy E2
Coil Line E1
Assy E1
Coil Line B1
Assy B1
Coil Line B2
Assy B2
Offices
Material Control
Lobby
Rest Area
Offices
Canteen
Offices
Rest Area
Offices
Canteen
Coil Line F
Assembly F
Coil Line C
Assembly C
Coil Line A
Assembly A
Coil Line D
Assembly D
Metal Line
Piping
Shop
Page 8
IE Workshop
Coil Line G & H
Insulation Area
Assembly H
Assembly G
Factory Capacity
Line
Product Range
Refrigerant
Type
Design
Capacity
Design
Capacity ( ½ Yr)
2009 Actual
Output ( ½ Yr)
Loading
Residential
Assembly B1
Single Split (0.75HP to 3HP)
Outdoor Unit
R22, R410A
339,300
169,650
127,994
75.45%
Assembly B2
Multi & Single split (2-6 HP)
Outdoor Unit
R22, R410A
156,600
78,300
45,191
57.72%
Assembly E1
Wall Mounted (0.7 to 3 HP)
Indoor Unit
N/A
287,100
143,550
91,606
63.81%
Assembly E2
Wall mounted (1 to 3 HP)
Indoor Unit
N/A
261,000
130,500
85,901
65.82%
1,044,000
522,000
350,692
67.18%
Sub Total
Light Commercial
Assembly C
Single split (3-6 hp)
Water Source (1-6HP)
Outdoor Unit
R22, R407C, R410A
117,450
58,725
37,926
64.58%
Assembly CE
Ceiling Expose (3-6 hp)
Ceiling Conceal
Indoor Unit
N/A
78,300
39,150
23,932
61.13%
Assembly F
Ceiling Cassette
Ceiling Expose E
Indoor Unit
N/A
99,180
49,590
37,007
74.63%
294,930
147,465
98,865
67.04%
Sub Total
Commercial
Assembly A
Outdoor/Indoor 5HP to 12HP
Outdoor & Indoor
unit
R22, R407C
20,880
10,440
6,803
65.16%
Assembly D
Outdoor/Indoor 15HP to 35HP Outdoor & Indoor
Rooftop 5HP to 12HP
unit
R22, R407C
10,440
5,220
2,262
43.33%
R22, R407C,
4,176
2,088
1,559
74.66%
35,496
17,748
10,624
59.86%
1,374,426
687,213
460,181
66.96%
Assembly H
Rooftop 15HP to 47HP
Indoor 40HP to 75HP
Outdoor & Indoor
unit
Sub Total
Overall Total
Page 9
Process Improvement Activities 1
•
Page 10
Acquired Production Daikin System (PDS) knowledge
5S Training
PDS Basic
Line Balancing
Kanban System Training
Process Improvement Activities 2

Kitting & Picking System
Residential Indoor
Residential Outdoor
Ceiling Exposed Indoor
Light Commercial Outdoor
Accessories Picking
Base Pan Picking
Blower Kitting
Base Pan Picking
Ceiling Cassette Panel
Ceiling Cassette
Commercial Outdoor
Package Unit
Parts Kitting
Parts Kitting
Metal Parts Picking
Piping Picking
Page 12
Quality Improvement 1

Acquired Japan Most Advanced Air Cond. Manufacturer Technology
Inverter Testing Module (Indoor Unit)
Indoor inverter testing ready
Inverter Testing Module (Outdoor Unit)
Single split inverter testing ready
Multi split inverter testing ready
*Included data logging
Page 13
Quality Improvement 2

Commercial Unit Air Tight Test fulfill PED Standard
Air Tight Testing Pressure
Refrigerant
Coil Line
Assembly Line
R22
3.29Mpa
1.55Mpa
R407c
3.29Mpa
1.78Mpa
R410a
4.19Mpa
2.51Mpa
Page 14
No operator is allowed inside the safety fence
while air tight test in progress for safety
purpose.
Quality Improvement 3

Packing Watch Dog – Be sure before we ship
High Side Label
Carton Label
Residential Indoor
Unit Label
Page 15
Residential Outdoor
③
Quality Improvement 4

Drawing Revised Example
Plastic fan (supplier drawing)
【Production, QC request】・・・Improvement of fan
vibration
・Each size of boss parts is not indicated
・Request to put in full length tolerance
200+0.0
-0.0
Φ15.0+0.06
-1.0
43.0
Indoor fan bearing
(OYL drawing)
23°
Φ14.0+0.075
-0.100
Page 16
【Revise contents】
・Append to detailed drawing & tolerance
・Hundreds of parts are measured by cooperation with
supplier, product evaluation is performed and tolerance
is determined.
【Supplier request】
・Part measures outside position (Φ14.0) is not clear.
・Request to unite outside(Φ14.0) tolerance with process
capacity
【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
OYLM Productivity Improvement
Domestic
Recovery
IncreaseSales
of local
sales
Increase
of local
sales
Economics
Crisis
Page 17
Quality Improvement
OYLM Market Defect Ratio 2009
Market Defect Ratio Percentage
2.5%
2.0%
1.99%
【Market Quality ・New Development Quality】
•On site checking (CY09: 40cases)which enable to find the root cause.
・Established the concurrent activity from which development
project leader took the lead.
•Drawing(revised 20pcs,CY09 )which reflect the opinion of supplier and
production dept. have improved.
・PJ (Pilot Judge meeting) and FJ (Final Judge meeting) have
been established certainly. At that time, we confirm past trouble
measure, drawing, parts receiving inspection, production preparation.
1.5%
1.0%
0.5%
1.30%
Descriptions
2007
2008
2009
Market Defect Ratio (All Products)
1.99%
1.30%
1.21%
-
-
Market Defect (Products in 2009)
Market Defect (New Products)
-
-
0.27%
0.27%
0.18%
0.18%
0.0%
Page 18
1.21%
2007
2008
2009
Quality Improvement
OYLM Manufacturing Defect Ratio 2009
Manufacturing Defect Ratio Percentage
3.0%
2.52%
2.5%
【Production Quality】
・Quality awareness (sense) of supervisors and workers
have been improved
・Workers can discover the fault by themselves
・The process has become easily to discover the fault
2.0%
1.53%
1.5%
0.93%
1.0%
0.5%
Descriptions
2007
2008
2009
Manufacturing Defect Ratio
2.52%
0.93%
1.51%
0.0%
Page 19
2007
2008
2009
Quality Improvement
OYLM Purchased Parts Defect Ratio 2009
0.40%
0.37%
Purchased Parts Ratio Percentage
0.35%
0.33%
0.30%
0.25%
0.20%
0.15%
0.10%
0.05%
【Purchasing Parts Quality】
・Creation of inspection standard (MIR)
・Communalization of OYLM receiving inspection items and
supplier delivery inspection items
・Periodical inspection at supplier (CY09:28times)
・These activities change constitution to prevent same problem.
Descriptions
2007
2008
2009
Purchased Parts Defect Ratio
0.37%
0.33%
0.23%
-
6 times
60 times
FTA Analysis
0.23%
0.00%
Page 20
2007
2008
2009
HR Development (HRD)
New Operator Training Program
Pre Orientation Test
Orientation Program
Skill Shop Training
(1 Day)
(2 Days)
(3 Days)
1st Day
•Orientation
•Company Background
•Rules & Regulation & Test
•Safety & Health Awareness & Test
1st Day
•Walk Test
•Run Test
•Stick Test
•Cards Test
2nd Day
•Basic of Air Conditioner & Test
•Environmental Awareness & Test
•OYLM Product
•5S Housekeeping & Test
•Motivation
Not Pass
Termination
Page 23
2nd Day
•Indoor Split Assembly & Test
3rd Day
•Outdoor Split Assembly & Test
Pass
Pass
Pass
Evaluation
1st Day
•Product Quality
•RoHS Compliance
•Accident Case
•Dangerous Materials
•Basic of Screw Driving & Test
Evaluation
Not Pass
Evaluation
Not Pass
To Line
HRD – New Operator Training
New Operator Training Program
Pre Orientation Test
Orientation Program
Skill Shop Training
(1 Day)
(2 Days)
(3 Days)
Walk Test
Stick Test & Card Test
Page 24
Orientation
Safety & Health Awareness
Screw Test
Outdoor Assembly Test
HRD – Special Skill Training
Special Skill Training Program
Brazing Training
Page 25
Required Nomination
Forklift Training
Wiring Training
HRD – Safety Training
Operator Safety Training Program
Importance of E-Stop
Pneumatic Pressure Test
Safety Training Table
24V Electrical Shock
Page 26
Chain Drive Pinching Force
HRD – Daikin Skill Pre-Olympic
Title : Daikin Asia Oceania Skill Pre-Olympic Competition 2009
Venue : Thailand
4th – Mr. Norhafiz
Page 27
Safety & Health Policy
Page 28
Safety & Health Activities
Page 29
Safety & Health Activities
Page 30
SAFETY & HEALTH MONTH
Safety & Health Week
Page 32
PPE WEEK
To educate employees
on selection, usage and
maintenance of PPE
HEALTH WEEK
Increase health awareness by
providing health screenings,
activities & exhibitions.
FORKLIFT COMPETITION
Enhance skills and knowledge in driving
forklift. Promote safety driving through
healthy competition.
Environmental Policy
3C4R
Page 33
Environmental Activities
Main Station Factory 2
Satellite Station Factory 1
Page 34
Environmental Activities
Page 37
Corporate Social Responsibility Activities
Page 38
O.Y.L. Manufacturing
THANK YOU
&
WELCOME
Page 39