PENJANA KPT-CAP:INDUSTRY CERTIFICATION ENGINEER - DIGITAL

ENGINEERING PROTOTYPING (ICE-DEP) PROGRAMME 2025

VEHICLE MANUFACTURING
PROCESS (VMP)
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Trainer
ENGKU AHMAD KAMEL
Senior Consultant

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 Introduction and Ice-breaking…
(video – 1.55min)
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 About the Trainer
Engku Kamel

Over 40 years of national and regional experience in Banking,

Oil & Gas, IT Consultancy, Automotive Manufacturing,
Outsourcing services and Economic Corridor Development,
managing a wide range of (retail) banking, Oil & Gas
downstream marketing activities, SAP system consultancy &
implementation, Automotive Systems management, Self-service
terminals outsourcing and Economic corridor development
activities; locally, regionally and internationally.
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 Program schedule

Course Duration – 1 day

Daily Schedule

Session 1 09:00am - 10:45am 105 min

Tea Break 10:45am - 11:00am 15 min
Session 2 10:45am - 01:00pm 35 min
Lunch Break 01:00pm - 02:00pm 60 min
Session 3 02:00pm - 03:45pm 90 min
Tea Break 03:30pm - 03:45pm 15 min
Session 4 03:45pm - 05:00pm 75 min
End of Session
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 Program overview

• Overview of Modern Techniques and

Technologies in VMP
• The importance of Automotive industry
to the country
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 Introduction

Brief overview of vehicle manufacturing

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 Electronics
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Forge
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 Covering many sectors…
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 Morning break…
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 Importance of Automotive
industry to Malaysia

The overall automotive industry and related

sectors employ around 710,000 people and
contributes almost RM30 billion to Malaysia’s GDP.
There are 38 manufacturing and assembly plants
producing passenger and commercial vehicles,
composite body sports cars, as well as
motorcycles and scooters - Miti
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 Automotive industry investments
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 History of vehicle manufacturing

Evolution from manual assembly to

automation
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 Vehicle manufacturing then & now
Discuss the differences (video – 1.12 mins)
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 How are cars made? (video - 5.54 mins)
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 Vehicle types

• Passenger cars
• Commercial vehicles
• Electric and hybrid vehicles
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 Malaysia total NEW vehicle
productions – Outlook 2024

Market Variance
2024 (f) 2023 (a) %
Segment Units
Passenger
666,000 719,150 (53,160) (7.4)
Vehicles
Commercial
74,000 80,571 (6,571) (8.2)
Vehicles
Total
740,000 799,731 (58,731) (7.5)
Vehicles
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 Sales of xEV

Year Hybrid Electric Total

2021 7,875 278 8,153

2022 19.988 2,631 22,629

2023 28,055 10.159 38,055

Note: Sales from MAA members only for the period

Number of charging stations:

• As of Oct 2023: 1,434 units (1,117 AC; 317 DC)
• Target by 2025: 10,000 units (9,000 AC; 1,000 DV)
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 Lunch break…
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 Design & engineering

• Importance of R&D in vehicle design

• Use of CAD (Computer-Aided Design)
tools
• Prototyping and simulation
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 Evolution of car design
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 Use of CAD in design

Computer-Aided Design (CAD)

technology. CAD has
revolutionized the automotive
design process, offering a
blend of precision, efficiency,
and flexibility.

Benefits :

1. Conceptualize the dream

2. Collaboration &
Integration
3. Auto Testing & safety
4. Customization to
consumer
5. Fast time to market
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 Material selection

• Common materials: steel, aluminum,

composites
• Considerations for weight, strength, and
cost
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 Business Case: How F1 influence
the automotive industry
The innovations born in the crucible of F1 often find their way into
mainstream automotive technology, shaping the cars we drive on our daily
commutes.

Enhance performance on Materials and weight Real-time data collection

the track but also improve reduction in Formula 1 has and analysis techniques,
fuel efficiency also driven advancements have been instrumental
in automotive in enhancing vehicle
manufacturing diagnostics, predictive
maintenance, and
improving safety and
reliability
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 Fabrication techniques

Stamping
Moulding
Welding
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 Toyota fabrication process
(video – 5.04 mins)
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 Assembly line process

• Flow of assembly line manufacturing

• Role of automation and robotics
• Just-in-time production
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 Just in time
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 Some interesting facts…

30,000 parts to build an average ICE car and

roughly half that number for an EV

By 2050, the number of cars on the world’s road could

swell from around 1.4 billion to more than 2 billion
vehicles. The 1955 Mercedes-Benz 300 SLR Uhlenhaut Coupe
Prototype sold for $142 million in 2022.

A new car body rolls off the body-in-white workstation at

GAC Motor’s Yi-chang factory every 46 seconds
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 Painting and finishing

• Steps in surface preparation

• Paint application methods
• Quality control in finishing processes
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 Painting process
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 Quality control measures

• Importance of quality assurance

• Testing methods: durability, safety,
emissions
• Industry standards and certifications
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 Car inspection

Certified
quality
inspectors
perform up

to1,500 -

point checks
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 Afternoon tea break…
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 Lean manufacturing principles

• Overview of lean principles

• Benefits of reducing waste and
increasing efficiency
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 Toyota lean manufacturing
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 Sustainability in manufacturing

• Eco-friendly materials and processes

• Reducing carbon footprint
• Recycling and end-of-life vehicle
management
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 …from design to disposal
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 Impact of technology

• Role of Industry 4.0 and IoT

• Use of AI and machine learning in
production
• Future trends: automation and smart
factories
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 Global supply chain

• Importance of a robust supply chain

• Challenges: sourcing, logistics, and
geopolitical issues
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 Key Challenges
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 Case study on leading
manufacturers

Overview of a few key manufacturers (e.g.

Toyota, Tesla, etc); What are the
innovations and practices that set them
apart?
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 Some other key challenges

• Rising costs of raw materials

• Meeting regulatory requirements
• Adapting to consumer preferences
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 Future of vehicle manufacturing

• Emerging technologies: electric vehicles,

autonomous driving
• Trends shaping the future of
manufacturing
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 Vehicle automation levels
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 Final recap

• Recap of key points

• The evolving landscape of vehicle
manufacturing
• Questions and discussion
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 for further enquiries please contact
ZOHL Consultancy Sdn Bhd
M2-15-02, Level 15, 8trium Tower 2
Jalan Cempaka SD 12/5, Bandar Sri Damansara
52200 Kuala Lumpur

T : 03.6279.9276 F : 03.6279.0663 E : training@[Link]

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Contact Person : Niesa/Hanisah (013.398.1038)

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