DRX: Proton Iswara 4G15P - An Installer's Choice

DRX: PROTON ISWARA 4G15P - AN INSTALLER CHOICE

In Malaysia, the NGV industry started on the Proton Iswara (4G15P engine) and remains as the best choice for NGV Installation or Conversion. The Proton Iswara is cheap, reliable and plentiful of spare parts. The conversion process is simple and relatively quick. However so, the conversion process should take around 1 complete day with 1 hands-on installer.

The 4G15P (1,500cc) engine is robust (tough) and durable (tolerant with extreme engine heat), and work well with NGV systems. Its smaller brother is 4G13P or 1,300cc models. Both engines are found in Proton Saga (Magma & Megavalve), Proton Iswara (Saloon & Aeroback), early Proton Wira (Saloon & Aeroback) and Proton Satria (non-GTI). It is a simple carburetor engine, and commonly found it Proton vehicle between 1980 - 1995.

If you are using a Proton Iswara, there is nothing to worry as it is the TOP and BEST vehicle to convert, and run in NGV. The track-record stands at 70% taxicabs in Kuala Lumpur city, and operating beyond 8 years now. It is still the most favourite model among taxi drivers based on both NGV reliability, cost of maintenance and drivability.

In fact, I have been using my 10 Years Proton Iswara Saloon (1,500 AT) over 4 years on NGV driving. By comparison, my usage is 90% NGV for all driving conditions and as little as 10% on petrol. Petrol is used during start-ups (for purpose of cleaning/lubricating intake & exhaust valves) when I keep my car with petrol during night parkings. This also helps to maintain the healthy condition of my carburetor device by lubricating internal rubber seals and gaskets.

A 4G15P Engine By Proton Malaysia (5-Star rating NGV Engine)

Base-Model for Installer Training into NGV Conversion






An Accurate 4G15P Venturi Mixer (Designed by Hijau Casko)






A 'Pig-tail' at 90 Degree Pipe Turns (for Accident Break-Proofing)






A Pig-Tail reduces Vibration, improve Flexible Piping Requirements





DRX: Hijau Implements 'Plug & Play' with Socket Systems

Commonly, the Malaysian NGV installers operate with a quick-fit and 'Plug & PRAY' approach on NGV conversions. In fact, installers use cut, tie and black-tape approach in all conversions. In my opinion, this is highly unethical and unprofessional. It is really an UNCERTIFIED approach. Thus, I have successfully implemented 'Plug & Play' technology into Hijau Standard Installation Procedure (H-SIP) and avoided 'Plug & PRAY'. The implementation of this P&Play is difficult as it brings conversion cost up, where each socket set costs around RM3.00. H-SIP requires 7 socket sets on a Proton Iswara alone. It a price uncompetitive between 'Plug & Play' -long-term Reliable & Durablility and 'Plug & PRAY'.

'Plug & Play' technology is implemented after we have conducted our R&D on NGV system operating in Tropical Climate, like Malaysia and Indonesia. Here is why we decided to adopt this expensive approach:

(a) The manufacturer wiring is thin (14 copper core strains), which becomes high current resistance during 3:00pm on a hot afternoon. Our sample cars provided a 48% current (Amperes) dropped at engine compartment temperature way over 200 Celsius. Our cars lost power mainly to closing of the gas solenoid (an electrovalve) and engine overheating. The radiator remains at 90 Celsius as reported by the Temperature Indicator; and

(b) A Cut, Paste & Black-Tape approach can lead to electrical sparking during an unfortunate auto accident. Socket system prevent sparking as it just discoonnect during a hard crash. NGV Gas will ignite if there is an electrical spark, flame rate well over 500 Celsius. This is why we termed it as 'Plug & PRAY' approach.

I believe that customer pays the best, MUST gets the best. That is best in safety features, reliable to use and easy to maintain as well as low-cost to repair in long term. Those who want cheap are often referred to shop around at other installers, as these customers are too ignorant to know 'people are profiting on their igorance'.

Back in 2007, I once asked why 'Plug & PLAY' is so popular around more installers. I was expecting an answer that it is fast-to-convert and extreme low-cost. Surprisingly, several installer answered to a similar tune, 'Kalau tidak ada masalah, mana ada business repair untuk jadi regular customer' or 'If not auto problems, where will there be NGV repair business as regular customers'. I was completely speechless.

In fact, we just want to meet our regular customers for routine services. These routine services include oil change, tuning and calibration and a chit-chat about NGV. It is a community of NGV Users, where Phillip Ng and I started off NGV Community.com for this reason.

'Plug & Play' - A Simple Rule: Well Designed & Neat

Fuel Selector Switch : Petrol or NGV (Bi-Fuel)

YES! We operate on either Petrol or NGV at one time. Once we have emptied our gas, we can drive back on petrol but it feels 'SINFUL' to use petrol. Mathematically, it is RM0.05 per km (NGV) against a sinful petrol RM0.20 per km. Why pay 70% more money, when NGV is more subsidized than petrol in this manner.

What is my advise on Proton Iswara Owners on NGV conversion?

Just get it done. You will not be alone, as i have converted 4 years back along with 30,000 other Proton Iswara taxicabs in Malaysia. You will NOT be the FIRST and it is not BLEEDING-EDGE technology on 4G15P engines!

Be Safe, Drive Safe

Dr Xander Thong

email: drxander@ngv.com.my

DRX: Klang Bad-Hat (Case 2007)

DRX: Klang Bad-Hat Installer & Honda Accord 2.0VTEC

Each year, I view and diagnose tens of NGV vehicle installed beyond Hijau. It is surprising that Malaysian Installers do not comply to any standard, such as United Nation ECE Regulation 110 (or R110) and Malaysian SIRIM MS1096:1997. In fact, the Malaysian MS1096:1997 is mainly based on NZ5422, and it is referred as Code of Practice For Use of CNG Fuel in Internal Combustion Engines (First Revision). For the guideline, I will prepare a comprehensive posting on how to install NGV system in accordance to SIRIM MS1096:1997 on a Mercedes Benz W126 (260E) later on.

In 2007, many problematic NGV vehicle approached us at Hijau for second opinion. Among hundreds of vehicle, there is one car that beat it all in areas of poor installation, unsafe, no sound engineering practices and worst, a complete mess. This is a case of a Honda Accord EX 2.0 VTEC belong to a Medical Doctor.

Originally, this Honda Accord VTEC was installed with a NGV Mixer system. It is a primitive system that turns the car into a carburetor engine while on gas mode. At petrol mode, it will be an electronic fuel injection (EFI). In our case, the Honda Accord VTEC owner complained that the car suffers from engine backfiring (explosions inside the engine) and great loss of power. It is a struggle to keep the car idling well and often stalled. Thus, we conducted a diagnosis on the car via Visual Inspection Method, on whether the car comply to SIRIM MS1096:1997 specifications.

The first thing we did was to check on the most important area of the complaints; the engine compartment and NGV system. Here is what we saw:

The Engine Compartment - NGV System

The NGV Reducer unit was placed on the right side of the engine, just behind the right-side main headlights. The NGV refilling nozzle is located at the same place with a red dust cap in the above picture. All hoses are long and look identical to a python snake in the engine compartment. It is a mess, and likely converted by a lazy, unexperience or untrained installer. In most cases, the installer companies employs school drop-out, SPM-education labourer or 'on-the-job-training' staff. Installation are done without proper supervision or instruction.

The hoses are in length of 5 feet and above.

The installation employed a messy configuration with wiring exposed and hoses being dangerously near to drive belts, especially the power steering pump. The gas hose from reducer to mixer is more than 6 feet long, resulting to great power loss, unstable idling and frequent engine stalling. The experience of backfire is the outcome of carburetor-on-gas at a VTEC engine. In reality, VTEC engine needs to use a Sequential Injection System (SIS), or commonly know as Electronic Gas Fuel Injection (EGFI).

In this case, the Honda Accord VTEC owner was hookwinked into using an unappropriate NGV Mixer system as his original installer did not know how to install SIS. Until today, many installers are able to install a SIS but unable to make it work properly. NGV Mixer system demands 80% mechanical ability and 20% programming. As compared with, SIS requires 20% mechanical ability and 80% programming/calibration. So, this case was a pure situation of wrongfully using incorrect system on Honda Accord VTEC engine.

But again, this is first part of many faults detected. The next area is the CNG cylinder installation. To our horror, his installer was clearly lazy to do a good and safe installation. This is how.

Wrong Screw Mounting Points on the Bracket

The installer drilled the mounting screw on the body floor slopping up or at the spare tire vault. This is 500% incorrect as it will cause tearing on the sheet metal body. This is against the requirement of SIRIM MS1096:1997 clause 4.3.1. This is one issue on the cylinder installation, and below is the next.

Cheap & Thin Screw on Clamping Mount and Numerous Welding Points

Now, it is clear why I recognised this Honda Accord VTEC as a case-study for 2007. It is top the worst installation over 12 months, among hundreds of vehicle I have seen. This is the works of a Klang installer, G**d***ck NGV. But this is not the end of our fault list. Here are more to view.

Single Screw Mounting vs SIRIM MS1097 Double Screw Mount

This is surely a quick-install method by using single screw mounting method. But SIRIM MS1096:1997 provides a 'securely attached to the vehicle to prevent slipping, rotating and jarring loose'. It means a double screw mounting is required on NGV refilling nozzle.

Exposed Wiring to Engine Heat

In many cases, electronic devices are installed inside the engine compartment. It is the area that endure extreme engine heat, which damages electronic diode, resistor, capacity and circuit relays. This is how NGV electronic fails in most situations.

Unsecured High Pressure Pipe Line - A dangerous Scenario

This is simple to expain. Look at how the high pressure pipe dropped down when I remove the rear wheel assembly to access the bottom body floor for cylinder mounting. It is an accident waiting to happen on a Medical Doctor. Hence, I had to remove the entire NGV system installed, from the cylinder to the engine bay. Everything came off the car, and rebuild to meet SIRIM MS1096:1997 standards.

It took 2 days to remove, and another 4 days to install a SIS. Here is the outcome, which subsequently cost the Medical Doctor - G**d**ck at RM4,800 + Hijau Repair & SIS at RM5,000. Total cost of RM9,800. A high price to pay for simply selecting an Installer.

Removal of Rear Wheel System for Proper Cylinder Bracket Installation

NGV Refilling Nozzle & 'Pigh-Tail' for Collapsing Pipe during Accidents

A Sequential Injection System on a Honda Accord VTEC-i

Every 3-4 months, Medical Doctor will come visit us at our office for a regular engine service. Our private satisfaction is when customers are happy driving their reliable and fuel saving vehicle. After all, it is 'Hijau Always Safe, Hijau Always $ave' that bring us conversion quality.

Be Safe, Drive Safe.DRX

email: drxander@ngv.com.my

DRX: Batu Cave Bad-Hat (Case 2006)

DRX : Batu Cave Bad-Hat Installer & Mercedes Benz W126 (Case 2006)

In 2006, I have encountered many bad-hats installers who operate their installation companies solely on profit-greed and minus vehicle safety. During this timeframe, there are only 14 licensed NGV workshop around malaysia and 60+ NGV stations. Some bad-hat installers were converting vehicle beyond their technical knowledge. Many choose to 'MacGuyver' method on their customers' vehicles. Here is one case worth mentioning out of many cases seen and assisted back then.

Around June 2006, I have received a telephone called from a Mercedes Benz W126 owner, Mr Steven Wong, whom explained that his vehicle is experiencing massive power-loss. Here was he problem then:

Vehicle: Mercedes Benz 280SEL

Engine: W126 (6 cylinder inline, or popularly known as black engine)

Fuel System: Bosch K-Jetronics (Semi-Injection or Fuel Divider)

Size: 2,800 cc

Age: 20+ years

Ownership: 3rd owner under his name

His Complains were: His 280SEL has unstable engine performance in the morning, where he needs to operate his car at least 10 minutes on petrol mode. After that, he need to switch back to petrol on hill-climbs, during traffic jams and carrying more than 3 persons on board. In addition, his 280SEL would stall when he reverses his vehicle or conduct a full-steering turn. His top speed on flat road (or highway) at 60kmph and MRR2 highway uphill ramps at 10kmph. Often, his idling is very unstable and difficult to drive. He has endured this problem for 3-4 months, and has visited his installer for 10-20 times in 3 months. The common answer 'Your W126 engine has problems, not NGV system' given by his Batu Cave Installer.

Here is what we have found during our routine diagnostic of his problem.

Picture 1: A Pipe in replacement of a K-Jetronic NGV Mixer
Bad-Hat Installer called it as 'Universal Pipe'. Elegant as it sounded

This particular 280SEL is installed with a Landi Renzo TN-1SIC reducer (oversize) which needs a proper NGV mixer to function properly. However so, his bad-hat installer installed a rubber pipe, and named it elegantly as 'Universal Pipe' or less gracious, 'Multipurpose Pipe'. Plainly, a mixer device create vacuum by itself (based on Venturi effect), and pulling in the correct amount of gas to the K-Jetronic airflow. In layman's term, the mixer is needed to determine the right amount of gas on the Landi Renzo reducer that should be supplied to the K-Jetronic (or gas-on-demand). No rubber pipe would function with Venturi Effect. It is just a pipe!

The solution is to remove the 'Universal Pipe' and have it replaced with an imported K-Jetronic NGV Mixer. It was specially flown in for the 280SEL in August 2006.

Picture 2: Power Valve & K-Jetronic Mixer (right)

The cost of importing this special mixer was at Euro100.00, inclusive of the power valve. The order took about 2 months to arrive.

Picture 3: The NGV Mixer sits on the mouth of the K-Jetronic

The NGV Mixer is designed to sit on the K-Jetronic mouth. The airfilter casing will be installed around it and fitting nicely in between the airfilter and the K-Jetronics.

Picture 4: NGV Mixer is sealed with quick-dry casket silicon

No air should be allowed to leak into the NGV Mixer at the gap between the NGV Mixer bottom and the K-Jetronic mouth piece. If there is a leak, the venturi effect would be reduced and the engine response will be delayed.

Picture 5: NGV Mixer and Airfliter casing

Due to original hole made for the 'Universal Pipe', we were limited to reuse the hole for our mixer connection. It took me about 5 years to get the hole resize and corrected for our mixer unit attachment. We were not able to introduce a new hole as it is dictated that we reused the original hole, although it is highly inefficient. Thus, it is very costly and time-consuming if a NGV vehicle is installed improperly.

Picture 6: Mercedes Benz W126 completed with K-Jetronic Mixer

Immediately, the engine idling was stable and the power output was good. Later we added a Timing Advance Processor to advance the 280SEL ignition timing. This lead to more power improves, drivability and stable idling. The vehicle still feel heavy as it is a heavy and old vehicle. It no longer suffer problems like low speed, poor uphill climb and engine stalling.

The total bill was RM900.00 on equipment, excluding labour cost. It took me and another installer, Thierry Le Marrec, about 6 hours to complete the entire repair process. And it was really hard as the original installer ignored all safe installaton methods.

We hope that potential NGV users consider properly on their choice of NGV installers. Please do NOT expect cheap conversion price is the best; in fact, it is the worst package. It is likely that you are getting a Universal Pipe than a K-Jetronic Mixer! It is not the first case, and it has NOT been the last too. There are about 50+ Mercedes Benz W124/126 are still experiencing problem with their cars.

Be Safe, Drive Safe. DRX

email: drxander@ngv.com.my

DRX: NGV Growth Inefficiencies (Malaysia)

DRX: NGV Growth Inefficiencies (A Malaysian Story)

'If we have made obvious mistakes, we should not try, as we generally do, to gloss them over, or to find something to excuse them; we should admit to ourselves that we have committed faults, and open our eyes wide to their enormity, in order that we firmly resolve to avoid them in time to come'. Arthur Schnopenhauer (1788-1860)

Being 4 years in Malaysia NGV industry, it have been observed that many growth inefficiencies are plaquing the Malaysian NGV industry. These inefficiencies are hampering steady growth in terms of consumer safety and confidence, good conversion practices, excellence aftersales services and stable proftable for installation companies.

The top elements that stop NGV growth dead in its tracks are Ignorance, Unethical and Negligence (or we termed them as NGV Evils). The combination of the three evils are lethal and fatal when it comes into as a single package. This deadly package is Accidents at NGV Stations.

In most cases, the accidents are not related to NGV system. It is the fault of human ignorance, unethical installations and downright negligence by either vehicle owner, installer or both. Here are the cases in point:

29 November 2008: 1st Accident involving NGV vehicle

It has been reported and found that the vehicle owner has been carried an Oxy-Acetylene cylinder in his boot. Firstly, the vehicle owner was ignorant that oxy-acetylene cylinder must be transported with open-ventilation. He took a convenient way, and put into the boot of his Mercedes Benz W124. Coupled with the hot boot temperature and the heating up of the NGV cylinder (during refilling), the oxy-acetylene cylinder exploded. Unfortunately, it happened at a NGV Station in Kuala Lumpur, and giving a perception that NGV can exploded. This is a called of pure human ignorance about transporting flamable items.

10 August 2008: 2nd Accident involving NGV Vehicle

A welder had his vehicle installed with a NGV system properly, but he decided to increase the gas storage capacity by using home cooking or LPG cylinder. Based on his complete ignorance of NGV system, he thought that LPG cylinder is similar to CNG cylinders. Immediately, the LPG cylinder exploded in seconds of refilling. Since he was in front of the vehicle (at frontal refilling), he escaped injury. This welder helped seal the faith for the NGV growth to doom. After this accident, consumers are worried by NGV system being a time-bomb and conversion sales dropped. This 2nd accident is a strong case of ignorance and negligence. A welder should have known better than to play with high pressure gas with low pressure LPG cylinders.

DRX: Safety Ads on NGV Community.com Magazine

The only action that I can take was to write up a Safety Reminder on the 2nd last page in NGV Community.com magazine (written by myself), reminding people the differences between low pressure tank and NGV cylinders. But again, human ignorance and negligence happened for the 3rd time.

7 November 2008: 3rd Accident involving NGV Vehicle

In fact, this accident did not happened on a NGV vehicle. It caused a young life of Mohd Hailmi Ishak - 25, whose his wife was just 2 months pregnant. Firstly, it started with the negligence of a Malaccan Licensed Installer that sold a NGV conversion system indiscriminately. The installer wanted to profit RM80 for trading the NGV system, directly to Allahyaham Mohd Hailmi (untrained NGV installer or appropriately - a consumer). As for Allahyaham Mohd Hailmi, he did not know that LPG cylinder can not be used as CNG cylinders. This led to a massive explosion, killing Mohd Hailmi several hours later with severe injury. Again, it is a classic case of human ignorance and the negligence by the greedy installer.

Personally, I am trying to resolve this human ignorance. The only solution available for me was to provide formal training to interested party. Universiti Kuala Lumpur Malaysia France Institute (UniKL-MFI) helped me accomplish this goal by having a joint certification programme for NGV Course. Perhaps, this is the 1st step toward reducing or eliminating Human Ignorance in NGV industry.

DRX: Education is the 1st Step to Ignorance Elimination.

With human ignorance and negligence, the NGV growth rate is commonly reversed. Accidents with LPG cylinder (or air compressor tank) stop the NGV growing. Unfortunately, greedy is the root cause of NGV growth inefficiencies.

In this posting, it is clear that human ignorance and negligence constitute 2/3 of the NGV growth inefficiencies. The final elements is unethical installations, which lead to routine vehicle breakdown, road accidents due to sudden engine stalling and others. Unethical installation is the hardest to eradicate.

Be Safe, Drive Safe. DRX

email: drxander@ngv.com.my

DRX: NGV Economics Drivers in Malaysia

DRX: A Journey Back To Economics Textbook

It has been 15 years now since I last read my Economics Textbook, back then in pursuing a BSc Economics. The first thing that we, amateur economist, learnt was that 'Economics meant the social science that studies the production, distribution, and consumption of goods and services.' A famous theory is the basic supply and demand model. The theory of demand and supply is a simple principle to explain prices and quantities of goods sold and changes thereof in a market economy.

In truth, economics is boring, confusing and downright hard. But nothing is harder than operating in Malaysian NGV industry without fundamentals in economics.

NGV Economics Drivers in Malaysia

In Malaysia, I have observed that Malaysian NGV industry is driven by 3 economic drivers:

(a) Changes in Petrol/Diesel Retail Prices (Petrol Price factor);

(b) Changes in the health of Malaysian Economy (Cashflow factor); and

(c) Changes in Consumerism toward Reputed Installer (Confidence factor);

Changes in Petrol/Diesel Retail Prices (Petrol Price Factor)

This Petrol Price factor was well demonstrated on 4th June 2008, where Malaysian retail petrol price increased 40% from RM1.92 to RM2.70 per liter. The demand for NGV conversion shot up overnight, and brought about over-demand symptoms.

The existing NGV Installer (licensed, rogue & unlicensed) was crowded with demand, and flushed with booking monies. It was the D-Day victory for all NGV installers, except Hijau.

Surprising to others, Hijau completely stopped all conversion activities by Board of Director, under my advice. Back in February 2006, petrol price risen from RM1.62 to RM1.92 brought about over-demand. Behind this over-demand, there is a big catch (or economic fallacy).

I have observed in February 2006 (Hijau Awakening) that many ill-maintained private vehicle by their owners would rush for NGV conversion. Eventually, these customers became a Warranty & After-Sales Service nightmare to their respective installers. Many workshops experienced 'come-back' complaints and started to incur huge time loss, under-conversion and sometimes warranty on non-NGV parts. The cause is commonly poorly maintained engines, where most owners are thrifty on service schedule. NGV conversion was their quick-fix to contain their financial problems, ballooning by higher petrol price.

Hijau kept itself outside this vicious demand as petrol price factor is very elastic (or its propensity (speed) to change is extremely high). A decision that Hijau made has proven to be right at the moment of writting this posting.

Although so, the petrol price increased spurred on new entrants (new entrepeneurs) into the Malaysian NGV industry. Many are illegal and almost all commenced business when petrol prices were failling down steadily.

Suddenly, petrol prices are reduced gradually from RM2.70, RM2.55, RM2.40, RM2.30, RM2.15 and at this day, RM2.00 per liter. The reverse petrol price factor prove fatal for unprepared installers (and that accounts for 98% of the existing installers, except Hijau).

I have always maintained that Hijau should be prepared for low petrol price factor, as well as increase gas price. Petrol Price factor in NGV economics is too unstructured, volatile and often unpredictable situation (as it is politically driven).

Changes in the health of Malaysian Economy (Cashflow factor)

With the global financial turmoil 2008 taking landfall in early 2009, the Malaysian economy is expected to experience a slowdown. It is expected to be a prolong world recession, where New Zealand, Singapore, Japan, Iceland and other countries has announced economic recession.

This brings about a slow but non-volatile cashflow factor. Individual and companies are cash-tight, where cash collection is poor (sometimes bad-debt) and cash outflow is a must on paying petrol. Thus, NGV conversion led to a 60-70% petrol discount, by using mainly natural gas.

Often, I have been criticised as 'Doctor on the outside, idiot in the inside', it is a clear fact that cashflow factor will drive more companies to use NGV as their cost-cutting practice. Company vehicles can't stop or travel-less, which incidentally means lower sales or reduce new cash streams. But cashflow factor demands strong foundation (good company brandname, technological reliable & excellence after sales service), and well-planned marketing.

Changes in Consumerism toward Reputed Installer (Confidence factor)

'To win Confidence in advance of Conversion Success is the hardest Accomplishment'. DRX

As posted earlier in DRX 2006: Discovering NGV in Malaysia, a NGV conversion company must have a positive reputation in the Malaysian NGV market. Private vehicle owners are new to NGV conversion, and based their purchasing on company reputation. Some customers may be more price-sensitive, while others are safe-conscious. Confidence can drive customers to NGV installer, provided that the reputation is positive.

At Hijau, 'Hijau Always Safe, Hijau Always $ave' is the source of our commitment and confidence. But the effort to obtain such Confidence is long and hard, frequently punctuated by criticisms from competitors. And for my reading competitors, here is what I have to say in return (to those unconstructive critics):

'In Hijau 2nd Rules there is only one clause:

DO WHAT YOU WILL,

because people who are free, well-born, well-bred and easy in honest company have a natural spur and instinct which drives them to virtuous deeds and deflects them from vice; and this I called Honour.'

This is our reputation, confidence and honour. Remember that, competitors!

Be safe, Drive Safe. DRX

email: drxander@ngv.com.my

DRX 2008: Disciplines in Safety and Hijau Quality

Discipline Through SOP, SIP and SLP


Since April 2007, Hijau managers encountered major problems with the operational employees whom were sales, administration and engineering workforce. There was confusion among the employees and company policies are frequently ignored by employee for their own convenience.


There is a need to develop Standard Company Policies, pertaining to:


(a) Standard Operation Procedures (SOP)
The SOP was developed and continuously reviewed to provide a standard policy on sales, finance and administration activities. Without a SOP, salesmen can over-commit on installation appointments, while Finance Department will be drained off money unnecessarily.


(b) Standard Installation Procedures (SIP)
The SIP was developed and to be reviewed by SIRIM (Malaysian Standard Board) for Malaysia Standard (MS) status. The SIP are Hijau standard documents on NGV conversion design, safety parameters, installation procedures, minimum component quality and delivery control. This is the key manual for all Hijau conversions.


(c) Standard Logistics Procedures (SLP)
The SLP is being developed to manage, administer and delivery components to franchisee, resellers and local stockist. This area still requires alot of attention after investment exercise.

or visit http://www.ngv.com.my/default.asp?pageid=190 under Procedures





Improved Franchise Model

Hijau managers have developed the brand name of Bumi Hijau (or Green Earth) as the franchise name. However so, there is a lacking of franchise expertise and knowledge among the Hijau managers. In this matter, Francorp (Franchise Consultant) has been invited to quote on the following services:
(a) Technology & Standard Procedures licensing;
(b) Franchise Royalty Payment;
(c) Outstation Support Charges;
(d) Sales Commission Scheme;
(e) Top Sales Bonus Scheme; and
(f) Other policies.

At present, we are testing and commissioning various parts of Franchise Programme in 2008. It is easy to claim franchise, but difficult to be profitable.

The key ideas of Bumi Hijau Franchise are:

(1) Hijau Franchisor operates as the Sales Principal (developing marketing materials, e.g. brochures) while the franchisees act as the front line agents. Both online and offline Hijau marketing will push conversion/service customers to the franchisees. After all, most franchisees are either business investors or auto-mechanics, lacking in time or sales ability to obtain customers on their own.

(2) Hijau Franchisor spend money and time on continuous Conversion Design, Research & Tropicalised Technology Development (or R&D) as the Technology Innovator while the franchisees are the new innovation implementers.

(3) Hijau Franchisor functions as the Conversion System Developer (building internal conversion standards like SOP/SIP/SLP) and Group Quality Controller while the franchisees convert under these Systems Approaches. These systems are designed for safe, reliable and responsible conversions by Hijau and Bumi Hijau Franchisees. All systems are derived from the based rules: Rule 1: Hijau Always Safe; Rule 2: Hijau Always $ave; Rule 3: Rule 1 Always Come First.

(4) Hijau Franchisor guides by acting as Principal Trainer while the franchisees must continuously upgrade their knowledge and improved methods (or Continuous Installer Education - CIE). Automobile technologies improve over time; thus, Hijau is perpuately advancing ourselves and franchisees through foreign trainers.

Foreign Technical Team Training

Hijau managers organise bi-annual foreign technical team training on various conversion products and/ or latest technologies. These trainings are offered to local authorities like PUSPAKOM, JPJ Technical, SIRIM and others. This is to assist the local authorities to enhance their knowledge about NGV conversion and safety.

Mr Naseem Khan from AutoLPG Installer (United Kingdom)

Rectifying Conversion Faults

Hijau managers had their fair share of many conversion faults, through Italian conversion methods. It is found that Italian conversion methods are susceptible to damage or problem in Malaysian hot climates.

Thus, Hijau managers reengineered the conversion methods and termed it as ‘NGV Tropicalised Method’. This includes the usage of customised wiring harness on carburetor vehicles, 3-in-1 NGV electronic control unit (ECU) and special calibration tools.

Specific Market Development

Hijau managers have found that most installers operating unprofitable are employing multi-model conversion approach. These installers often experienced come-back customer complaining of problems or undrivability. Their inexperiences are producing unreliable conversion methods.

For profitability, a focus strategy is needed. Thus, Hijau managers conducted a Specific Market Development Plan on the following criterias:

i) Vehicle volume is substantial (above 100,000 units on the road now);
ii) Single deal for large vehicle number of conversion (fleet); and
iii) After conversion teething problems at lowest (low come-back jobs).

Hijau manager have always identifed the following vehicle models that meet the criteria:
(1) Nissan Vanette C22 Carburetor (rating : 5 out of 5)
(2) Proton Iswara 1.3 & 1.5 Carburetor (rating : 4 out of 5)
(3) Toyota Unser 1.8 GL Simple EFI (rating : 3 out of 5)
(4) Mercedes Benz W124/W126` Carburetor (rating : 2 out of 5)
(5) Toyota Hiace 2.0 (1RZ) Carburetor (rating : 1 out of 5)

Besides so, Hijau has redesigned NGV Tropicalised Methods into 12 other models. Each models has been designed, endurance tested for safety and reliability. This is already 2 - 3 years on most prototype models.

Be safe, Drive Safe. DRX

email: drxander@ngv.com.my

DRX 2007: Interacting with NGV Users

DRX 2007: Interacting with NGV Users

Certified Installers Vs Rogue Installers

There is an acute shortage of certified installers in Malaysia. Presently, we have alot of rogue installers, converting vehicle recklessly and unsafe practices. In fact, rogue installers protect their little know-how as a dark art.

Thus, there is a need to establish a formal training on NGV. Hijau managers have decided to pursue a collaboration with Malaysia France Institute, under Universiti Kuala Lumpur (UniKL).

Pre-Franchise Modelling

There is a need to establish a franchise chain of Hijau workshops, specialising on promoting Safe NGV Conversion. Many NGV Installers have tried to use franchise as a method of building up network of workshops, but failed. It has been determined that they do not established the following elements:

(a) Corporate Culture, like Hijau Always Safe, Hijau Always $ave, which translated that Hijau demands safety and provide reasonably priced after conversion services;

(b) Operational Manual, like Standard Installation Procedures (SIP), Standard Logistics Procedures (SLP) and Standard Operational Procedures (SOP), which determine a conformity among all Hijau workshops; and

(c) Unique Products, NGV conversion kit and specific cylinders sizes, which is solely distributed by Hijau.

During this phase, the Pre-Franchise Modelling was pre-mature and contained many gaps. It is in April 2007 that Hijau Managers are able to develop the above considerations.

(a) Search of Technical Assistance

Hijau managers accepted that Hijau can be weak in many areas of NGV conversion. Thus, it is imperative to obtain technical assistance from overseas installers. The areas that needed foreign technical assistance and advisory. In January 2008, Hijau managers have achieved a host of foreign technical assistance:

i. Mr Naseem Khan (AutoLPG, United Kingdom);
ii. Mr Dag Tenter (Autogas, Germany);
iii. Mr Carlo Carlini (Gascontrol, Italy);
iv. Mr Edwin Low (ITE, Singapore);
v. Mr Chistopher Tan (Scantruck, Singapore);
vi. Mr Lim Sin Leng (Green Pacific, Singapore); and
vii. Mr Suchai Lormongkhonkit (Greensiam, Thailand).

Hijau Thai and Singaporean Experts



Hijau Briton & Turkish Experts



Industry Benchmarking Ideas


Hijau managers have been unsuccessful to find a NGV conversion workshop as a benchmark standard. Hence, Hijau proceeded into developing its industry benchmarking ideas on Malaysian NGV standards:

i. Benchmarking websites as the primary marketing tool in 2007 and 2008;
ii. Benchmarking conversion method with high reliability after conversions;
iii. Benchmarking after sales service with user tutorial services;
iv. Benchmarking industry as installer company with immediate replacement parts;
v. Benchmarking training syllabus for practical knowledge; and
vi. Benchmarking marketing materials and marketing slogans.



Hijau Carburetor Brochure



Hijau EFI-Mixer Brochure



Hijau EFI-SGI Brochure






Be Safe, Drive Safe. DRX
email: drxander@ngv.com.my

DRX 2006: Discovering NGV in Malaysia

DRX 2006: Discovering NGV in Malaysia

The Hijau managers entered the market with no historical direction as a guideline. There is no visible NGV business model during April 2006 onwards. All NGV businesses are small-time, cottage-industry installer, operating out of small workshops.

Thus, Hijau managers needed to learn from the industry in discovering its secrets, logics and obstacles. The learning phase is the difficult and costly without income generation ability. At this phase we have found out the following knowledge:

(a) NGV Key Success Factors
The successful NGV Business must consist of the following:

1st Success: Brand Name in Malaysian NGV Industry
There is no recognisable brandname for NGV Installer, pertaining to safety, professionalism, knowledge and after sales reliability. This is the 1st and most important success factor. Hijau managers started working on building a brandname, Hijau, into the Malaysian NGV industry from April 2006, via websites:

http://www.ngvcommunity.com/

http://www.ngv.com.my/

2nd Success: Conversion Quality, Standards & Workmanship

The NGV conversion business consists of many rogue installer, who are operating irresponsibly and recklessly at times. Vehicles are converted without the proper components, where DIY parts are often used. This lead to many undrivability and frequently engine stalling

Rogue Installers Workmanship


No mixer or 'Universal Pipe'

Hijau Installer Workmanship

K-Jetronic Mixer (W124)

Hijau Manager reworked all conversion procedures, and developed the Hijau Standard Installation Procedure (H-SIP) to comply with UN ECE R110 and MS 1096. The conversion procedures have been reengineered for high reliability or problem-free after conversion.

3rd Success: Professional, Clean And Green NGV Workshop

Hijau managers have learnt that clean and professional workshop is a must. In our case, it is also very Green in colour, which is signify Green Evironment in the West, as well as Green for Islamic. Both East and West are acceptable to a green (or ‘hijau’ in Malaysia language).

The Prototype Hijau workshop was designed to be pleasant for female customers, as well as culturally acceptable to male customers and children. The concept was derived from ‘shfting values’ into going Green, going Hijau. The workshop design and decor took 12 months to be perfected, and established on 1 May 2007.

NGV is not just about savings, but also promoting green as per Hijau marketing.

Hijau Prototype Conversion Workshop (Kuala Lumpur, malaysia)

NGV Key Market Direction

Malaysian NGV industry has always been leaderless and lack a national direction. Since 4 June 2008, the industry remains in a 'search pattern' for business direction. Although so, Hijau managers have always set the direction for the NGV industry as promoting ‘Safety Comes First’.

Due to Hijau’s Safety Awareness web campaigns, Hijau is being known for a Safety-conscious NGV Installer. Many consumers are attracted to Hijau Always Safe, Hijau Always $ave policy, which in turn benchmarked the industry safety standards. However so, rogue installer remains to conversion recklessly, while rogue importers are selling indiscriminately.

The Key Market Direction is heading, and soon demanding, safety conversion. It is quality conversion against quantity conversion. Hijau manager, Dr Xander Thong, has been quoted on New Strait Time Newspaper as saying:

‘Safety & Reliable conversion is at the expense of Installer’s Profit, while Cheap conversion is at the total expense of safety and reliability’.

Safe Conversion. This is the consumer direction. And this is the governmental direction. This is the sole and only direction Hijau.

Be Safe, Drive Safe. DRX

email:drxander@ngv.com.my

DRX 2005: Lonely Green Proton Iswara NGV

'When Curiosity turns to serious matters, it's simply called Research'.

'Why are we the only private NGV car queuing with the taxicabs?' enquired my wife, Mrs DRX. A look around brought about the reality that my Green Proton Iswara NGV was the only private car with NGV installed, queuing up with 8 taxicabs. That's was in 2005 when petrol price was steadily at RM1.32 per liter.

My Proton Iswara NGV was converted under license, G*m*ri Auto Service. Back then, I did not have the authorised Conversion License to convert my own vehicle. Thus, my Proton Iswara had to experience the works of unprofessional installer, and later undergone a massive repair (or mildly said, retrofit) by my own.

Sample areas of Retrofit (to re-install the NGV properly) by myself, a Qualified NGV Installer.

Sloppy High Pressure Pipe Routing - 1

Sloppy High Pressure Pipe Routing - 2

Half-Rubber Padding (short-cheat)

Besides the above problems, a long list can be written in regards to poor installation methods and short-cheat components (and missing safety components). Yes, the vehicle passed Puspakom as it was not their fault since no Puspakom inspector was ever trained on NGV. In fact, it was a good thing that Puspakom allow a 'Pass' on my conversion, and had my Vehicle Grant endorsed as Petrol/NGV status. This helps me obtained my Vehicle Insurance protection.

DRX Retrofit: Pig-tails at NGV Reducer & Refilling Valve

(This provides Flexibility in NGV Pipe during Frontal/side Accidents)

Under SIRIM 1096:1997, these pig-tails are referred as Flexible Hosing/Piping. The intention is to allow the pipes to be bent (or coiled like a spring) during accident without breaking and preventing high pressure methane gas rushing out into the damaged engine (and possibly burning engine compartment).

My own retrofitting took about 1 week, as sourcing the spare parts were near impossible. The limited importers were not cooperative and not willing to provide the parts, like:

(a) high pressure pipe and bicones (need to replace the old 'G*m*ri' pipes);

(b) built a customised wiring harness, using Normally Closed relays (constant & direct battery);

(c) replace the cylinder rubber padding and high tension bolts/nuts to DIN8.8 specs;

(d) replace the Air-Fuel Mixer to a Fixed Venturi type; and

(e) installed a Timing Advance Processor (Joker-N Type) from AEB Srl.

This experience led to one commitment: Dr Xander Thong will make 'NGV Always Safe, then NGV Always $ave' for all NGV Users. Since I viewed NGV as Green (or Hijau), it is naturally translated into Hijau Always Safe, Hijau Always $ave.

In 2006, Hijau was established as 'Momoweb MOG Sdn Bhd' where momoweb stood for Mo-mobile, Mo-motion and Web-worldwideweb. It is observed that NGV vehicle was always on the move (mobile), the industry constantly changing (motion) and the web should be the place to gather all NGV users together. This has led to NGV Commmunity.com (http://www.ngvcommunity.com/) and Hijau (http://www.ngv.com.my/).

By 2007, Momoweb MOG Sdn Bhd was upgraded to its maiden name, HIJAU MOG. Curiously, MOG stands for Malaysian bioOil & CNGas. Both my lonely Green Proton Iswara and Hijau started to promote 'Hijau/NGV Always Safe, after that Hijau/NGV Always $ave'.

Our Curiosity on how to ensure safe, reliable & responsible conversion lead to our Research of 'NGV Tropicalisation' technologies in Malaysia. This has taken us at, Hijau, 3 years and alot of self-determination. To know Hijau, it is just remember Hijau Rules of NGV Engagement:

Rule 1 : Hijau Always Safe

Rule 2 : Hijau Always $ave

Rule 3 : Rule 1 Always Come First.

Be Safe & Drive safe, DRX.

email: drxander@ngv.com.my