Honda Malaysia Pegoh Plant was constructed on an 80-acre land with a total built-up area of 12.4 acres. It is divided into 3 zones i.e. the main plant that houses the CKD (Complete Knock Down Unit) assembly plant and its auxiliary buildings, the CVJ (Constant Velocity Joint) plant, and the CBU (Complete Built-Up Unit) pre-delivery operation.

Focusing on environmental-friendliness, quality and cost competitiveness, self-reliability and conduciveness, the plant was constructed to realise Honda’s long-term vision, that is to become a major player in the ASEAN region.

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  CKD

  Material Services is responsible for the control of the CKD parts; such as receiving and delivery, otherwise known as Total Inbound Logistics within the plant. Honda Malaysia operates its CKD operation from internal resources to ensure cost target being achieved accordingly.

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  Welding

  Welding is divided into 3 zones, Zone 1 - Sub-component (under body), Zone 2 - Side frame and main body, and Zone 3 - Shell/fitting, all comprising of approximately 20 processes. Utilization of Honda’s Capacity Production Method ensures a consistent quality although equipment is operated manually. With two robots installed to ensure a spot point of the highest consistency and accuracy of the wheel arch, a commonised line can cater up to 5 types of white body model.

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  Paint Shop

  The paintshop is built up for 20,000 units yearly, but it is now available to accommodate 40,000 units. It is separated into 3 zones, Zone 1 (Pre-Treatment and ED), Zone 2 (Spray booth and working areas) and Zone 3 (Ovens). A robotic system for primer and clear coating to ensure consistent application and finishing, was successfully introduced and Zone 2 was upgraded to accommodate 25,000 units a year. It is also convertible to facilitate water borne paint application when the need arises.

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  Assembly Engine

  Considered the heart of Honda, it is built with air-conditioning system and special facilities to maintain a clean environment. This section consists of 14 processes / stations including sub-assembly and firing, endurance test promises an engine of highest quality. Although the line production is operated manually, the U-shaped layout is still the first of its kind in Honda ASIA.

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  Assembly Frame

  This Assembly is divided into 3 zones, namely Trim, Chassis and Final. The Trim zone involves both sub-assembly and main assembly of preliminary parts such as brake pipe, seatbelts, roof lining and floor carpets; Chassis caters for docking of engine; FR and RR suspension installation, under body part installation, tyre installation and filling of Honda Special Brake Fluid. The Final zone assembles the final parts such as window glass, door panels and seats. This zone is equipped with a seat manipulator to assist with front seat installation; it is also equipped with a special Honda immobilizer.

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  Vehicle Quality

  This department is responsible for assuring the highest quality of completely built-up cars. There are 10 processes with usage of various equipment; exterior, interior, wheel alignment and headlight adjustment, speedometer and brake test, side slip test, under body inspection and water leakage inspection. LET inspection technology is also used to detect electrical and technology function failure, which humans can’t detect.

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  Test Track

  The test track is the 8th Inspection process from the total of 10 inspection processes in Honda Malaysia. This process is divided into 2 categories: High-speed course (along the 2 kilometres of 2 way drive up at 140km/h) and Multi-condition bad track which consists of: Low resistance tract, Belgian road, Cobble stone road, Hummy road, Pave road and Pool test area.