1.

0 Background of Sanyco Grand Industries Sdn Bhd

1.1 Introduction

Sanyco Grand Industries Sdn Bhd was establish on 14 May 1991 with initial revenue
about RM10 Million and paid reveneue about RM5 Milion. Initially, the company was located at
Pandamaran Industrial Park which located in Klang, Selangor Darul Ehsan. On 1997, the
company was moved to new factory which located in Hicom Glenmarie Industrial Park. At
beginning, the business operation of the this company is to supply imported component that are
needed by buyers from San Yes Automotive Cooperation Limited that operated in Taiwan. Due
to excellence performance of business, this company was entrusted to become one subsidiary of
SMIS Corporation Berhad with another two subsidiary that is Grand Carpet Industries Sdn Bhd
and MIS Sdn Bhd. Now, the main businesss of Sanyco Grand Industries Sdn Bhd is to produce
and supply automotive component such as automotive hydraulic braking components, hydraulic
clutch components and motorcycle component. This company also listed in second board of
Bursa Saham Kuala Lumpur (BSKL). The main customers is Perusahaan Otomobil Nasional
Berhad (PROTON), Hong Leong Yamaha Motor, Perusahaan Otomobil Kedua Sdn Bhd
(PERODUA), TRW (TOYOTA), Sapura Brake Technologies Sdn Bhd and Oriental-Hyundai
Sdn Bhd.
2.0 PRODUCTS
2.1 This company was produce main automotive brake component.
2.1.1 Brake Master Cylinder and Brake Master Duplex
This product function is part of braking system as control
device that converts non-hydraulic pressure (commonly
from a driver's foot) into hydraulic pressure. This device
controls slave cylinders located at the other end of the
hydraulic system.

2.1.2 Clutch Master

The clutch master cylinder is a device that transforms

mechanical force into hydraulic pressure. As the driver
presses the clutch pedal, the pedal lever applies force to the
clutch master cylinder which transmits hydraulic pressure to
the clutch release (slave) cylinder that disconnects engine
power to the transmission.

2.1.3 Proportioning valve

The proportioning valve is to reduces the pressure to the rear brakes. Regardless of what type of
brakes a car has, usually the rear brakes require less force than the front brakes.
3.0 MANUFATURING PROCESS AND PRODUCTION SYSTEM
In this company, there are four main department involved to produce certain product, the
department are casting department, machining department, assembly department and quality
control department. All of this department are responsible to ensure every product that have been
produce to follow all the specification required.

Figure: Flow of production process for

products
3.1 Casting Department
In this department, all the component must undergo casting process to obtain initial shape of
component. The main material that have been use to produce the components is AC2B and
AC4CH types of Aluminum.
Ingot
Selection

Melting

Pouring

Cutting

Heat
Treatment

Hardness
Test

a. Ingot selection
A process where aluminum were chosen and weighed before melted
into crucible.

b. Melting
The process where aluminum ingots were melted in
crucible, usually the temperature needed to melt the
aluminum around 700 degree Celsius.

c. Pouring
Melt aluminum or as known as Molten were poured into mold. In this process, the machine that
were use is Gravity Machine.
d. Cutting
In this process, parts that are not needed on
product were removed by using grinder or
vertical and horizontal bandsaw.

3.2 Machining Department

In machining department, there are 4 types of machining division called line, the 4 types of line
are called line 1, line 2, line 3 and line 4. Every line is responsible to process certain
component. For example for line 1, this division are required to process machining activity on
brake master cylinder and for line 2 are responsible for machining activity of proportioning
valve component. The production plan of manufacturing division are visualize on figure below.

LINE 4

LINE 3

LINE 2

LINE 1

Product finish after machining process

Product from casting department enter line of

production

Figure: Division flow in machining

department

At every line, there are few type of machining process involve in producing component
for example drilling, milling, tapping, lathe, reaming and slot cutting. Every machining process
were done by using Computer Numerical Control machines (CNC). In this department, every
part of machining process was called station. Usually, at every line, there were 8 type of station
were located, every station are responsible for every machining process for certain part on a
component. For example, to produce brake master cylinder, there are few types of machining
process involve such as drilling, boring, reaming and tapping.
3.3 Assembly Department
This department were divided into 3 division called visual check section, child part sub
assy section and assembly section, at every section, there are only one operator that are
responsible to operate every section.
a.

Visual check

The section where all component that have been machined will be inspect to identify the
defect occur such as burr, scratch, dimension does not follow specification required and others.
b.

Child part sub assy

All the child part are assembly with others child part
before attach to brake component. In this section the
assembly process of child part will be done by
operator.

c.

Assembly line

In this section, the child part that

have been assembly will be attach on
brake component that have been
machined. The type of assembly process
is tube seat insert, stamping, bore
greasing, reservoir seal insert, clevis
length adjustment,
After all the assembly process have been
done, the component will undergo the
quality inspection of the component in
term of performance of the component
such as lost travel test, leakage test and
vacuum test.

Figure: Layout of company plan

4.0 REFERENCES
1. Madam Melissa Wong, Assistant Manager of Human Resources Department, Sanyco Grand
Industries Sdn Bhd.
2. Laporan Latihan Industries Grand Industries Sdn Bhd
3. Webpage
a. http://aisinaftermarket.com/uploads/file376.pdf
b. http://en.wikipedia.org/wiki/Master_cylinder