Proton does a Toyota with Kaizen and Proton Production Way, starts manufacturing improvement plan at Tanjung Malim EV plant, rollout in 2027

Proton has introduced a new manufacturing improvement programme at its Tanjung Malim EV plant, focusing on preventing defects, improving production efficiency, and developing employees’ skills.

Called the Proton Meta Power 5-Star Programme, the initiative starts with a pilot at the EV facility before expanding progressively to other plant operations in Tanjung Malim from 2027.

The approach places greater responsibility with employees at each workstation. Workers are encouraged to check their own work, prevent defects from reaching the next production station and look after their equipment. They will also help colleagues develop their skills and raise issues that affect daily operations.

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Proton CEO Dr Li Chunrong said technology alone would not determine the company’s manufacturing performance, with employees’ skills and commitment remaining central to producing vehicles consistently.

The programme builds on the Proton Production Way, the company’s manufacturing framework covering safety, quality, cost, delivery and morale. Its scope includes operating standards, equipment control, employee development and quality checks throughout production.

Proton Meta Power adds a structured system for teams to develop those capabilities and apply them consistently on the factory floor.

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Central to this is the 5-Star Team system, which assesses teams against defined standards and recognises their progress. Performance will be measured through workplace safety, product quality, cost efficiency, equipment reliability, delivery performance and employee skills.

Managers and supervisors will be expected to coach their teams, support problem-solving and encourage suggestions. Proton says assessments must be regular, fair and transparent, with employee development given attention alongside production targets.

The initiative also brings together existing improvement activities, including Kaizen, workplace organisation through 5S, and autonomous maintenance, where employees take a more active role in caring for production equipment.

Workers can flag issues through problem-solving tickets and employee proposals. A separate Heart & Voice Community provides a channel for sharing concerns and ideas with management, which is expected to respond, take action and communicate the outcome.

Proton says the programme also supports Malaysia’s Technical and Vocational Education and Training (TVET) objectives by developing workers’ capabilities in manufacturing increasingly technology-intensive vehicles.

The EV plant’s pilot assessment is targeted for completion by December 2026. Lessons from the pilot will guide the wider rollout, with Proton aiming to establish 5-Star capability across the participating Tanjung Malim plant operations by October 2027.

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