Sheet 07 — Delivered works
3projects shown — before and after, with the measured outcome.
Glove manufacturer, Kamunting
Condition found
Obsolete controller, no program backup, HMI dead — line run on manual pushbuttons after every trip.
Delivered
Omron CP2E CPU with NB7W HMI, recipe screens for four glove grades, program listing handed over.
Outcome
Grade changeover cut from 40 min to 12 min; unplanned stops down 60% over six months.
Palm kernel mill, Manjung
Condition found
Forty-year-old MCC, unlabelled starters, no as-built drawing, repeated overload nuisance trips.
Delivered
New MCC built at Tasek, VSDs on three conveyors, full labelling and DWG as-builts.
Outcome
Cut over inside a 36-hour shutdown window with zero rework calls.
Logistics DC, Ipoh
Condition found
Seized gravity rollers, misaligned frame, cartons jamming at the transfer.
Delivered
96 galvanised Ø50.8 mm rollers, frame re-aligned, two driven drum motors at the transfer.
Outcome
Jams at the transfer effectively eliminated; throughput back to design rate.