Sheikh Brothers Industries Sdn. Bhd. (SBI) assembles in house. Child parts — felts, foams, sealers, covers — are supplied by manufacturers or bought by SBI from outside suppliers, then fitted to the mother parts SBI molds, welded where the part calls for it, and packed to a set quantity per polybox. Surface texture is cut into the mold itself; painting goes to outside companies.
Child parts
Everything fitted to a molded part arrives from outside. SBI receives it and fits it on its own stations.
- Source
- Supplied by manufacturers, or bought by SBI from outside suppliers
- Examples
- Felts, foams, EPT sealer, lids and covers, PP corrugated board
- Fitted to
- Mother parts molded by SBI
Assembly
Each assembly is built at a manual station from one work instruction sheet, then packed to the quantity that sheet sets.
Examples
- HVAC case
- Door foot and centre cover fitted to the molded case; grease applied by brush.
- Battery cover sub-assembly
- PP corrugated board clamped in a jig and ultrasonically welded, then foam bonded to it. 30 per polybox.
- Rear combi trim
- Lid and felt fitted, part bagged. 12 per polybox.
- Quarter vent duct
- 590 mm EPT sealer fitted and smoothed with a scraper; both butterflies checked and marked. 40 per polybox, in three layers.
Method
- Stations
- Manual, one work instruction sheet posted at each
- Instructions
- Step photographs, child parts, equipment, packing standard and the defects to reject
- Kanban chart
- At the station, for operators to reference during assembly
- Welding
- Ultrasonic, with the parts held in a clamping jig
Texturing
Texture is not a separate step. It is cut into the mold, so every part comes off the press with its finish.
- Molds
- Bought from moldmakers
- Texture
- Built into the mold to the customer's specification, where the part calls for one
Painting
- Carried out by
- Outside painting companies, engaged by SBI