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A CROSS SECTIONAL STUDY ON PERFORMANCE ASSESSMENT ON KUCHIN G MANUFACTURING

INDUSTRIES: A TIME SERIES ANALYSIS

Benjamin Bong Lip Jin

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UNIVERSITI MALAYSIA SARA W AK

R13a

BORANG PENGESAHAN STATUS THESIS

Judul: A Cross Sectional Study on Performance Assessment on Kuching Manufacturing Industries: A Time Series Analysis

SESI PENGAJIAN: 2009/2010

Saya BENJAMIN BONG LIP JIN

(HURUF BESAR)

Mengaku membenarkan tesis * ini disimpan di Pusat Khidmat MakJumat Akademik, Universiti Malaysia Sarawak dengan syarat-syarat kegunaan seperti berikut:

1. Tesis adalah hakmilik Universiti Malaysia Sarawak.

2. Pusat Khidmat Maklumat Akademik, Universiti Malaysia Sarawak dibenarkan membuat salinan untuk tujuan pengajian sahaja.

3. Membuat pendigitan untuk membangunkan Pangkalan Data kandungan Tempatan.

4. Pusat khidmat Maklumat Akademik, Universiti Malaysia Sarawak dibenarkan membuat salinan tesis ini sebagai bahan pertukaran an tara institusi pengajian tinggi.

5. ** Sila tandakan ( ..J) di kota yang berkenaan

D

SULIT (Mengandungi makJumat uang berdaIjah keselamatan atau kepentingan Malaysia seperti uang termaktub di dalam AKT A RAHSIA RASMI 1972).

D

TERHAD (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasiJ Badan di mana penyelidikan dijalankan).

O

TIDAK TERHAD

Disahkan oleh

(TANDATANGAN PENULIS) (TANDATANGAN PENYELIA)

Alamat tetap:

No.376 Lot239 Lorong7 Batu 5, lalan Semaba 93250 Kuching Sarawak

Dr. M. Shahidul Islam Nama Penyelia

I ~/" 'J U"fI/E . 20 10

Tarikh:

.

CATATAN· Tesis dimaksudkan sebagai tesis bagi Ijazah Doktor Falsafuh, Smjana dan Sarjana Muda.

•• Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasalorganisasi berkenaan dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai SULIT dan TERHAD.

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APPROVAL SHEET

This project report which entitled "A Cross Sectional Study on Perfonnance Assessment on Kuching Manufacturing Industries: A Time Series Analysis' was prepared by

Benjamin Bong Lip Jin (16028) is hereby read and approved by:

Dr. M. Shahidul Islam Date

Project Supervisor

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Puaat K.hidmat Mak.lumat Ak.adem~

UNIVERSITI MALAYSIA SARAWAIC

A Cross Sectional Study on Performance

Assessment on Kuching Manufacturing Industries:

A Time Series Analysis

BENJAMIN BONG LIP JIN

Thesis is submitted to

Faculty of Engineering, University Malaysia Sarawak In Partial Fulfillment of the Requirements For the Degree of Bachelor of Engineering

With Honours (Mechanical and Manufacturing Engineering) 2010

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To my beloved family and friends

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ACKNOWLEDGEMENT

I would like to express my appreciation to those who had given assistance and support throughout this entire project. Without their help and time given, this project will not be able to complete smoothly within the scheduled time.

First of all, I would like to thanks my supervisor, Dr. M. Shahidul Islam for all the guidance, advices and encouragement that was provided in order to ensure the project can be complete in time without troubles. I also would like to thank Faculty of Engineering, University Malaysia Sarawak for the facilities provided.

I would like to show my gratitude to the surveyed companies for willing to spend their valuable time to fill the questionnaires and provide important infonnation for this project. A special thanks for author's course mates and family for their morale support during this project.

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,..

ABSTRACT

The manufacturing industries in Malaysia became a significant contributor to the country's economy since the 1960s. The growth and structural changes in the manufacturing sector over the past forty years can be grouped into three main areas such

as the resource-based industries, labour-intensive industries and lastly the value added capital and knowledge-based industries. The purpose of this study is to examine the growth of potentials of the manufacturing industry of Sarawak. In order to get the essence of potentials of this sector, the questionnaire survey method was used to examine R&D capability, growth trend of skills of workforces and technical capability in Kuching and Samarahan area. Questionnaire was sent to manufacturing companies to be filled. The surveyed data was analyzed by using standard statistical tools. The result shows that most of the companies are non R&D. The major percent of manufacturing process are dependent on manual and semi automated operation system. The skill levels of workforces are significantly low compare to Peninsular. This result indicates, the importance of R&D to the ~~eyed industries is less compare to the main stream of Malaysian manufacturing industries. It is recommended that industries operating in Kuching need to set up R&D department and install automatic machineries in order to increase their performance. Moreover, the industries shall increase their skill level for increasing the manufacturing performance.

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ABSTRAK

,...

Sejak zaman 1960an, industri pembuatan telah menjadi sumber yang berpengaruh kepada ekonomi Malaysia. Pertumbuhan dan perubahan struktur dalam sektor perkilangan untuk empat puluh tahun kebelakangan ini dapat dikelompokkan kepada tiga bidang utama iaitu industri berasaskan sumber, industri berintensifkan buruh dan industri penambahan nilai. Tujuan kajian ini adalah untuk memeriksa pertumbuhan potensi pertumbuhan industri pembuatan di Sarawak. Untuk mendapat infonnasi tentang potensi-potensi sektor ini, kaedah kajian soal selidik telah digunakan untuk memeriksa keupayaan R&D, arah aliran pertumbuhan kemahiran tenaga kerja dan keupayaan teknikal dalam kawasan Kuching dan Samarahan. Soal selidik telah dihantar kepada syarikat-syarikat pembuatan untuk diisikan dan data berkenaan telah dianalisis dengan menggunakan alat-alat statistik standard. Keputusan menunjukkan kebanyakan syarikat yang ditinjau tidak mempunyai jabatan R&D. Kebanyakan proses pembuatan bergantung pada sistem operasi manual dan separuh diautomasikan. Tahap kemahiran tenaga kerja sang at rendah ~tbanding dengan Peninsular. Hasil ini menunjukkan kepentingan jabatan R&D untuk industri-industri yang ditinjau adalah lebih rendah berbanding dengan arus utama industri-industri pembuatan Malaysia. Syarikat-syarikat yang beroperasi dalam Kuching dinasihatkan untuk mendirikan jabatan R&D, memasang jentera-jentera automatik. Tambahan pula, industri-industri perlu meningkatkan tahap kemahiran pekerja untuk menambah prestasi pembuatan.

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CHAPTER 2 LITERATURE REVIEW

2.0 Background of Study 14

2.1 Measuring methodology of manufacturing productivity 15 2.2 Method of measuring Technical Efficiency 17 2.2.1 Outer-bound Production Function 18

2.2.2 Stochastic Frontier Model 19

2.2.3 Cobb-Douglas production function 21 2.3 Econometric Estimates of R&D's Contribution to Productivity

Growth 22

2.3.1 The Theoretical Framework 23

2.4 Method of Measuring Skill 25

2.4.1 Time Study 25

2.4.1 Work Sampling 26

2.4.3 Application of Learning Curve 28 2.4.4 Method of improving skills of labors 30

2.5 Research Objective 33

.~

CHAPTER 3 METHODOLOGY

3.0 Introduction 34

3.1 Data Collection Method 34

3.2 Principal steps of postal survey 35

3.3 Design of questions 43

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CHAPTER 4 RESULT AND DISCUSSION

4.0 Introduction 45

4.1 Examine the R&D Capability of Manufacturing Industries 46 4.1.1 The growth trend of skilled people in R&D department 47

4.1 .2 The investment on R&D activities 48

4.1.3 The growth trend of R&D program implementation 49

4.1.4 The number of research collaboration with other

research institutions 50

4.1.5 Identify research focusing area 51 4.2 Examine the Growth Trend of Skills in Manufacturing Industries

52 4.2.1 The implementation of external training program 53 4.2.2 The implementation of internal training program 55 4.2.3 ~growth trend of skilled worker in manufacturing

industries 57

4.2.4 The growth pattern of investment on skills development

program 59

4.3 Characterize the Technical Capability of Manufacturing Industries 61

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4.3.1 The growth trend of engineering staff in manufacturing

operations 62

4.3.2 The growth trend of automation in manufacturing

operation process 64

4.3.3 The growth trend of engineering management usage in

manufacturing industries 65

4.3.4 The growth trend of computer application in engineering management for operating manufacturing process 66

CHAPTER 5 CONCLUSION AND RECOMMENDATION

5.0 Introduction 67

5.1 Findings 67

5.2 Limitation of the Study 68

5.3 Contribution of the Study 68

5.4 Conclusion 69

5.5 Recommendation 69

5.6 Scope o~,,";lture Studies 70

REFERENCES 71

APPENDIX A 73

APPENDIX B 74

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LIST OF TABLES

Table Page

1.1 Real GOP by Sector 12

3.1 Sample of General Manufacturing Industries 39

3.2 Response Rate Analysis of Pilot Survey 42

3.3 List of Respondent Company 44

4.1 Number of skilled people in R&D department 48 4.2 Amount of money invested on increasing equipment capacity for conducting

R&D 49

4.3 Percentage of R&D implementation 50

4.4 Number of Research Collaborated with Other Nature 51

4.5 Research Area 52

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Appendix B

A Cross Sectional Study on Performance Assessment on Kuching Manufacturing Industries: A Time Series Analysis

uestionoaire

This questionnaire has four sections. The questions have been designed to get very specific findings of manufacturing growth (Kuching and Samarahan Area of Sarawak, Malaysia,). The main target of this study is to make Performance Assessment by find out the change of technical progress of manufacturing industries. The technical progress (TP) will be measured by using data of change in R&D capability (R & D), Skills change of workers involve in manufacturing process (SKI, the changes in operations capabilities and the change in manufacturing productivity (MP) of industries. Each section of this questionnaire is dedicated to meet the individual target of this study.

Section 1. The change in R&D capability of manufacturing industries (R & D)

To measure the progress in R&D capabilities, five parameters relating to R&D has been select.

In this section, question will ask you about your investment you have spent on Human capital development for doing R&D.

Q1.1. Please states the number of skilled researchers you have engaged in the following years to carry on R&D for your company. Please specify their average salary per month of this people in RM;

Category of Researcher 2000

I

2001 2002 2003 2004 2005 2006 2007 2008 Average Salary

m 5,Graduate(n) I

m 5 , Masters (n) ,

EY~ 5, PhD (n)

Note: EY~ indicates the exp eriencl"Ol the peopIe is not less than 5 years in research work Ql.2 Investment on increasing equipment capacity for conducting R&D, please specify the amount in RM;

Year/Investment 2000 2001 2002 2003 2004 ,2005 2006 2007 2008 Lab equipment(RM)

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Appendix B

Ql. 3 if any Implementation is made of research finding, please specify in percentage

Year 2000 2001 2002 2003 2004 2005 2006 2007 2008 Implementation (%)

Ql.4. If any research collaboration made in the given schedule, please state.

Year /Colleboration nature 1 2000 2001 2002 2003 2004 2005 2006 I

2007 2008 With University

With institutes

With same nature of manufacturing I

Ql. 5 Please specify the focus of your research

Focus of Research 2000 2001 2002 2003 2004 2005 2006 2007 2008 New Prodcu Development

Improve product Quality I !

Cost Redution i

Section 2. Skills change of workers involve in manufacturing process (SK),

To measure the Skills changes of workers involve in manufacturing process (SK) two parameters relating to Skills have been selected to observe the progress. In this section, question will ask you about your investment you have spent on training for developing skills of manufacturing worker.

Q.2.1 Please states, how many manufacturing workers have been trained externally in the given schedule? Please specify the number of workers;

Year/Types of workers

~~

2000 2001 2002 2003 2004 2005 20061 2007 2008

Unskilled(n) 1

Sem i-Skilled( n)

Skilled(n) I

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••

Appendix B

Q.2.2 Please states, how many manufacturing workers have been trained internally in the given schedule? Please specify the number of workers;

Types of workers 2000 2001 2002 2003 2004 2005 2006 2007 2008 Unskilled(n)

Semi-Skilled( n) Skilled(n)

Q.2.3 Please states, how many manufacturing workers was employed in your plant in the given schedule? Please specify the number of workers;

Types of workers 2000 2001 I 2002 2003 ,2004 2005 2006 2007 2008

Unskilled(n) I

Semi Skilled(n)

Skilled(n) I

Q.2.4 Please states the amount of RM your company spent during the specified period for developing skill of your workers

Types of workers 2000! 20011 1 2002 2003 2004 2005 2006

,

2007 2008

RMfor Unskilled I

RM for Semi Skilled I

RM for Skilled I

Section 3. The changes in plant operations and manufacturing capabilities

To measure the changes in Operations and Manufacturing capabilities five parameters have been selected. In this section, question will ask you about the technical capability of plant operations.

Q3.1 Please state, how many technically educated people you have engaged in manufacturing operations process. Kindly specify the number of workers;

Type Manufactuing staff 2000 2001 2002 2003 2004 2005 2006 2007'12008 I

Diploma(n) ,I

Vocational (n) Trade course(n) Engineering Gaduate

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Appendix B

Type machineries 2000

1

2001 2002 2003

1

2004

I

2005 2006 2007 ~ 2008

Manually operated Machine % Semi Automatic Machine %

Pic base Automatic Machine % I Analouge base control Machine %

03.4 Please states the use of computer in manufacturing planning process. Kindly specify in terms of percentage of use;

Type Activites 2000 2001 2002 2003 200412005 2006 2007 2008

Production planning and scheduling % I 1

Inventory control % Quality control % Report Making %

03.5 Pleases states the use of computer in manufacturing management system. Please specify in terms ofthe percentage of use;

Type in Activites

1

2000 2001 2002

I

1 2003

I

2004 2005 2006 2007 2008 Supply Chain Management %

Human Resources Management % Sales Planning and Evaluation %

Manufacturing growth Analysis % I

Section-4. The change in manufacturing productivity (MP) of industries

To measure the changes in manufacturing productivity the total direct manufacturing labor hours i.e working hours of manufa~Ulring staff and total gross output of the plant is considered Q 4.1 Please states the use of total direct manufacturing staff hours and the total output obtained from the plant in the given schedule.

Manufactuirng parameters 2000 2001 2002 2003 2004 2005 2006 2007 2008

Total gross output Quantity 1

Total direct manufacturing hour Quantity-in terms of number or tons

Thanks for given your value able time for supply the .import data.

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CHAPTERl

INTRODUCTION

1.0 INTRODUCTION

The structure of the Malaysian economy has achieved an amazing change after independence in 1957. It has changed from an agriculture-based economy, which highly depends on the primary commodities production for exports to a manufacturing based economy. The share of the agriculture sector in the Gross Domestic Product (GDP) dropped from 29 percent in 1970 to 13 percent in 1996 and further dropped to 8 percent in 2005. On the other hand, the share of the manufacturing sector jumped from 14 percent in 1970 to 35 percent in 1996 and increase to 40 percent in 2005 (Ministry of Finance, 2004). The manufacturing sector has now become the main contributor to the

.'

Malaysian GDP compare to the agricultural sector. The structure of employment has changed from concentration on agricultural activities to manufacturing industries and high labour intensive industries towards high capital-intensive industries. (Jajri, 2007)

The growth and structural changes in the manufacturing sector over the past forty years can be highlighted in three main areas. First, the resource-based industries, a re­

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channeling of resources changed from the processing of primary commodities, to a more non-resource-based industries and a slightly faster growth of resource-based industries in recent years. Agriculture's share of GDP has also declined sharply over this period with the growth of more non resource-based industries. These structural changes were made in the context of the observed phenomenon that Malaysia's agriculture's share of GDP had been given its level of income higher than would be considered to be the nonnal pattern in economic growth. Second area is the growth of more labour-intensive industries, especially with the growth and dominance of the electronics and electrical products industry and textiles. Third, in more recent years the strategic has been push to search for new growth areas and the push towards more high value added and knowledge-based industries with the erosion in Malaysia's comparative advantage in labour costs and labour intensive manufacturing industries. In recent years the growth of the resource-based industries continues to be promoted, especially with the encouragement and support given to biotechnology. (Yusof & Bhattasali, 2007)

The perfonnance of the Sarawak's economy has been remarkable over the years as reflected by the remarkable expansion of its GDP. It enjoyed positive growth though

.'

inconsistent at certain years, throughout the period from 1987 to 2002. However, the average growth of 5.6 percent for the period from 1988 to 1994 in the State was lower than the national average of 10.8 percent per annum. Fuelled by the surge in foreign investment especially in electronic industries and petrochemical, a high growth rate of approximately 11 percent took place in both 1995 and 1996. (Ngiik, N.D.)

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Nowadays, the concept of total factor productivity (TFP) growth is more emphasized in research in Malaysia. Total factor productivity (TFP) is the quantity of output divided by total of all the input. TFP studies appear to center on time series analysis of productivity growth in the manufacturing sector. The advantage of TFP is the ability to explain the productivity for the whole inputs used in the production process.

(Jajri, 2007) The focus on TFP growth is clearly set out in the Seventh Malaysian Plan (1.996-2000) and the Second Industrial Master Plan (1996-2005) which strongly emphasize the need to move forward from an investment-driven to a productivity-driven path. TFP also can be used to reflect the technologic progress in a country. The high investment in human capital and emphasize on the creation of a knowledge-based economy had improved the quality of labour in Malaysia, which allow it to contribute to the TFP. TFP has five key economic factors which is demand intensity, education and training, economic restructuring, capital structure, and technical progress.

Recent elaboration of the stochastic frontier model further decompose TFP growth into technical progress (TP), technical efficiency change (TEC) , allocative efficiency change (AEC), and scale efficiency change (SEC) (Kumbhakar 2000; Kim and Han 2001). In stochastic frontier models, changes in scale efficiency (SE) and allocative

efficiency (AE) arising from production scale and market distortions, respectively can affect TFP growth. Policymakers always recommend policies that can improve the productivity of businesses only if they understand the sources of variation in productivity growth. The proposed decomposition enables policymakers to trace those

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TFP growth, the production frontier can be shifted upward through investment 10 research and development; if slow productivity growth is traced primarily to deteriorating AE produces lower TFP growth, intervention that interfere with efficient business decisions should be modified or eliminated. Since Nishimizu and Page (1982), researchers have dec{)mposed TFP growth into efficiency changes and technical changes

using various data sets to investigate productivity growth. Bauer (1990) produced a translog cost frontier estimate using data on the US airline industry to decompose TFP growth into efficiency, technical progress, and scale components.

Total Productive Maintenance (TPM) has been recognized as one of the important operation strategy to regain the production losses due to equipment inefficiency. Many organizations have implemented TPM to improve their equipment efficiency in order to obtain the competitive advantage in the global market in tenns of cost and quality.

Efficiency and effectiveness of equipment plays a main role in modern manufacturing industry to determine the perfonnance of the organizational production function as well as the level of success achieved in the organization. For more than two decades, the development of the Malays~ manufacturing sector had registered an excellent performance and attracted a large number of foreign direct investments to this country.

These excellent perfonnances have allowed the Malaysian manufacturers to enjoy an important competitive advantage in the global market, especially in tenns of cost and quality. (Seng & Jantan, N.D.)

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Pusat KnlWllai. Mai .ana~ t\.k.adcIQiA.

UNIVEItSITI MALAVSIA SARAWA!(

There are several factors affecting productivity such as level of technology and socio-<iemographic. Other factors such as human resource development (HRD), human resource management (HRM) , institutional restructuring may also influence productivity. Malaysia's total R&D expenditures tripled in constant prices from RMO.8 billion in 1992, to RM2.5 billion in 2002 (calculated from MASTIC 2004).2 Around one third of total research investments were made by the public sector while the private sector accounted for the remaining two thirds. Most of this growth occurred after the national government launched its seventh five-year plan in 1996, which stressed the importance of science and technology for economic development. Three main commodity boards in Malaysia, the Malaysian Palm Oil Board (MPOB), the Malaysian Rubber Board (MRB), and the Malaysian Cocoa Board (MCB) have conduct research on Malaysia's principal export commodities under the administrative responsibility of the Ministry of Plantation Enterprises and Commodity (MPEC). In year 2002, these three boards together accounted for 20 percent of Malaysia's agricultural research and nearly one-third of the country's agricultural R&D expenditures. (Stads, Tawang, & Beintema, 2005)

..

Various measures of output and various measures of input can be used to measure productivity and the choice of the measure depends on the focus and the purpose of the analysis. Productivity presented as per capita GDP says more about societies' well being than productivity presented in terms of the output over input ratio. A shift-share based analysis is proposed with the aim of identifying the causes of the interregional aggregate

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share analysis is to investigate if the difference in growth between each region and the Dational average is due to the region performing uniformly better than the average on all industries or to the fact that the region happens to be specialized in fast growing sectors .

•1 Manufacturing Industries in Malaysia

The manufacturing industry in Malaysia became a significant contributor to the country's economy since the 1960s. During the colonial period, the country had been a major producer of raw materials, namely, tin and rubber. Today, the manufacturing sector is a dynamic and flourishing component of the national economy. Different industry and sector give economic contribution to the country.

1.1.1 Rubber Industry

Malaysia is the third biggest producer of natural rubber in the world. Malaysia complemented its market posit as one of the world major producer and exporter of natural rubber also leads in the manufacture of latex goods. The Malaysian rubber industry produces a broad range of products from natural rubber as well as rubberwood products. The manufacture of rubber-based products has attracted a constantly growing number of foreign manufacturers and investors around the world such as Good year of the United States and the Pirelli of Italy.

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.2 Food Industry

In Malaysia, the food, beverages and tobacco industries are the province of small ad medium scale establishments. Food manufacturing industries relies heavily on the imported inputs such as rice from Thailand, canned food from China. Efforts are required in order to encourage import substitution in this sector .

•1.3 Oil and Gas Sector

Malaysia is Southeast Asia's second largest oil producer after Indonesia.

Malaysia's oil and gas consumption stood at 514,000 barrels per day. Optimism is high for the petroleum industry and the manufacture of related products in Malaysia, in year 1998, there are five oil refineries in Malaysia: two are owned by PETRONAS, two by

Shcll and one by the Exxon Mobil. The Liquefied Natural Gas (LNG) plant at Bintulu, Sarawak owned by PETRONAS is the world's third-largest LNG exported.

1.1.4 Heavy Industry

The heavy-industry sector can trace its beginnings to the period of large-scale tin mining in peninsular Malaysia from the mid-nineteenth century. In 1967, the country's first integrated commercial steel mill (Malayawata Steel Bhd.) was established. Foreign vehicle giants like Toyota, Honda, and Volvo had assembly plants in Malaysia since the

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appearance of the Proton Saga in 1985 and Perodua Kancil in 1992. In Malaysia, Proton held more than 60 percent of the market share for automobiles throughout the 1990s .

.1.5 Timber Industry

The timber industry has contributed enormously to the overall economic development of Malaysia. The timber-based industries manufacture a wide range of

wood products including sawn timber, plywood, prefabricated houses, doors, window Dames, wall panels, fiberboard, particleboard, wood briquette and others. Furniture and wood fixtures are produced for the domestic and foreign markets.

L t.6 Chemical Industry

The chemical industry in Malaysia continues to rely on imported intermediate chemical and petrochemical products in production ranging from household items to

material inputs for the rubber, ~m-oil, and timber industries. The chemical industry sector has foreign participation including ICI, Unilever, Colgate Palmolive, Shell and others.

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