Honda Malaysia's Pegoh Plant was constructed on an 80-acre land with a total built-up area of 13 acres. It is divided into 3 zones i.e. the main plant that houses the Complete Knock Down Unit (CKD) assembly plant and its auxiliary buildings, the Constant Velocity Joint (CVJ) plant, and the Complete Built-Up Unit (CBU) 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, which is to become a major player in the ASEAN region.

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  Material Service

  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, Zone 2 - Sub Frame and Main Body, and Zone 3 - Fitting, all comprising of approximately 20 processes. Honda Global Standard equipments are widely used to ensure consistent quality at most efficient operation. Honda's unique General Welding Machine is used to guarantee white body accuracy to its best and commonisation of multi-model production. Robots were added to side-panel and re-spot to eliminate hard job and guarantee smooth spot points at all times.

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  Painting

  The painting facility, which was originally built for 25,000 units per year, has been expanded twice to its current capability of 35,000 units per year. It is divided into 3 zones; Water-based zone: pre-treatment and ED; Spray application zone: spray booth and working areas, and Hot zone: the ovens. The spray booths were constructed to facilitate the requirement of water borne application in the near future. Robotic spray application system was added at Primer and Topcoat application to ensure consistent application and finishing at all times; in addition to VOC reduction.

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  Assembly Engine

  Engines are assembled in an air-conditioning environment to maintain cleanliness at all times. All assembled engines are subject to 100% firing test, promising only engines of highest quality are fitted to the vehicles.

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  Assembly Frame

  The assembly frame is divided into 5 main processes with a total of 29 workstations. Wiring processes fit all the harnesses, Interior process fits all the interior trim parts, Underbody processes work with all the chassis parts, Exterior process for all the final fitting parts, and Complex process matches it all together. The workstations were designed to suit doorless operation and various manipulators and robotics were added to eliminate strenuous operation.

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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, and final 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 consist of: Low resistance track, Belgian road, Cobble stone road, Hummy road, Pave road and Pool test area.