Sample Report
Sample Report
Sample Report
KULLIYAH OF ENGINEERING
INTERNATIONAL ISLAMIC UNIVERSITI MALAYSIA
ACKNOWLEDGEMENTS
Assalamualaikum w.b.t.
All praises be to Allah, Lord of the Universe, the Merciful and Beneficent to
Prophet Muhammad S.A.W, His Companion and the people who follow His path.
First and foremost, I would like to take this opportunity to express my sincerely
gratitude and appreciation to my parents and my family for the support through my
university years. Special thanks are due to Sony EMCS Malaysia Sdn. Bhd. for
giving me a chance to undergo my industrial training. Thanks to my supervisor, Mr
Nizam Ramli and technicians for their guidance in order to successful in my
industrial training. My further gratitude is to all the engineers, team leaders and
technicians who have assisted me in completing this internship, especially in
completing my project. To the Student Industrial Internship Unit of International
Islamic University Malaysia, I would also like to take this chance to thank them for
organizing this course and help me in finding the host company, as it enables me to
widen my perspective on the real engineering and working world. Last but not least,
not to forget family and friends who gave me the supports towards the completion
this course and project. Thank you very much for the wonderful hands.
Thank You and Best Regards,
Faiz Naim B Rahamaddulla
Department of Material Engineering,
International Islamic University Malaysia
iii
TABLE OF CONTENTS
CHAPTER
CONTENT
PAGE
INDUSTRIAL VERIFICATION
ii
ACKNOWLEDGEMENTS
iii
TABLE OF CONTENTS
iv
LIST OF FIGURES
INTRODUCTION
1.1
1.1.1
Scope Of Training
1.1.2
Internship Objectives
1.1.3
Internship Goals
1.1.4
1.2
1.2.1
Sony
1.2.2
1.2.3
1.2.4
The Mission
1.2.5
1.2.6
History Of Sony
1.2.7
1.3
9
11
14
PROCESS FLOW
16
3.1
Introduction
16
3.1.2
16
LINE SETUP
22
4.1
Introduction
22
4.2
Process Flow
23
4.3.
ESS-04 Line
24
4.3.1
Line Layout
25
4.4
Table Setup
27
4.4.1
Types of Table
28
4.5.1
Material Setup
32
4.5.2
Equipment Setup
32
4.5..3
ByOff Process
32
4.5.4
32
4.5.5
Adjustment
33
4.5.6
Production
33
4.5.7
Improvement
33
4.5.8
34
SELF-ACTIVITIES
40
5.1
40
5.2
43
5.2.1
Introduction
43
5.2.2
Photosensor
44
5.2.3
Relay
44
DISCUSSION
45
RECOMMENDATION
47
7.1
47
7.1.1
47
7.2
48
7.2.1
48
7.2.2
Weekly Logbook
32
CONCLUSION
49
APPENDICES
51
LIST OF FIGURES
FIGURES
TITTLES
PAGE
1.2.1
1.2.6
3.1
19
3.2
21
4.1
23
4.3.1
25
4.3.2
26
4.4.1
Table 50
28
4.4.2
Table 90
29
4.4.3
Flatness Table
29
4.4.4
Railing Table
30
4.4.5
Packing Table
30
4.4.6
4.4.7
4.5.8
4.5.8.1
4.5.8.2
4.5.8.3
4.5.4
5.1.1
5.1.2
5.1.3
5.1.4
5.2.3
Packing Box
Packing Box
Line Balancing
CSOC Form
Cause and Effect Diagram
Movement Waste
Checklist Missing Items
PLC Box
PLC Box
Power Supply
Sensor
Circuit Diagram For Stopper Platen On Rail
CHAPTER 1
31
31
35
36
37
38
39
40
41
42
44
INTRODUCTION
1.1
1
1.1.1
SCOPE OF TRAINING
I.
II.
1.1.2
INTERNSHIP OBJECTIVES
2
To introduce students to work culture and industrial practices. In this
way, students would not have any problems in familiarizing and adapting
themselves in real working situation. Three months of working environment
allows students to sharpen their interactive skills and skills manipulation.
such as SONY. This can be a great advantage to students who are exposed to
experienced personnel where they can possibly learn and share new
knowledge.
1.1.3
INTERNSHIP GOALS
i)
ii)
iii)
3
1.1.4
Basically, the work, tasks or projects that are carried out during the
internship is closely related to downstream activity, which related with mechanical
and electronic course of engineering. The scope of works includes technical and
non-technical aspect, teamwork and individual tasks, leadership and management.
I.
II.
IV.
4
1.2 HOST COMPANY BACKGROUND
1.2.1
Founded by Masaru Ibuka and Akio Morita in 1958, the Sony Corporation
has come a long way since its first transistor radios. Being innovative thinkers, the
founders realized a need for a global brand with mass appeal. Hence, as the
company grew, it was simply logical to establish production facilities in their
respective regions. Since its inception, very few have been able to match Sony's
track record for invention and innovation. These include the first Trinitron colour
television (1968), the colour video-cassette (1971), the renowned Walkman (1979),
the world's first CD player (1982), the 3.5-inch floppy disk (1989) and many
others.Beginning 1st April 2004, Sony Electronic (M) Sdn. Bhd. Penang and Sony
(Technology) Sdn. Bhd. Bangi have merged into one company named Sony EMCS
(Malaysia) Sdn. Bhd. So, in Malaysia Sony have three sub plants at Prai Industrial
Estate, phase 1, Penang, as Sony EMCS (M) Sdn. Bhd. (PG Tec), Sony Kedah Plant
at Tikam Batu Industrial Estate, Kedah and Sony EMCS (M) Sdn. Bhd. (KL Tec) at
Bangi Kuala Lumpur. Name of EMCS means Engineering Manufacturing and
Customer Services
5
1.2.2
The name combining two words created Sony. One was the Latin word,
'sonus,' which is the root word for 'sound' and 'sonic.' The other was 'sunny,' meaning
little son. The name symbolizes Sony's spirit and motivation to stay committed to its
customers as well as to enhance its reputation in taking its innovations into the
future of digital technology.
Sony has helped developed discerning Malaysians who have come to expect
quality, integrity and reliability in audio/visual equipment. Sony's cutting-edge
technology brings sights and sounds, expectations and experiences into the home as
well as the office.
In line with Malaysia's VISION 2020, our future will focus on the dynamic
digital era with even sharper cutting-edge technology. The future is filled with
exciting promises for continuous and rapid growth.
1.2.3
The origin of Sony goes way back to May 1946. Back then, its original name was
Tokyo Tsushin Kogyo K.K. (Tokyo Telecommunications Engineering Corporation).
The founders, Masaru Ibuka and Akio Morita, wanted a name that can be easily
remembered by the world. This was essential to achieve success in the global
market. Their vision was for Sony to become an endearing household name across
theglobe. With this in mind, Morita came up with the term 'global localization' in
1988.
6
1.2.3
The Mission.
1.2.4
Sony's assets are neither its buildings, nor its land. Sony's greatest asset
is the image of the four letters: S-O-N-Y. Just as in the past, for Sony to
succeed in the future, it must raise its brand image and create innovative
products.
1.2.6
M = Manufacturing
CS = Customer Service
Figure 1.2.6
Sony EMCS Plants Map in Malaysia
8
1.2.7
Sony Company 5S
9
1.2.7.4 Phase 4 Seiketsu
Standardizing: Standardized work practices or operating in a consistent and
standardized fashion. Everyone knows exactly what his or her responsibilities
are to keep above 3Ss.
1.2.7.5 Phase 5 Shitsuke
Sustaining the discipline: Refers to maintaining and reviewing standards.
Once the previous 4Ss have been established, they become the new way to
operate. Maintain the focus on this new way of operating, and do not allow a
gradual decline back to the old ways of operating. However, when an issue
arises such as a suggested improvement, a new way of working, a new tool or
a new output requirement, then a review of the first 4Ss is appropriate.
CHAPTER 2
CHAPTER 3
PROCESS FLOW
3.1
INTRODUCTION
Process flow is the general work done by the operator at each station for each
line. At Peripheral Device (PD) department, the process flow is created by an
experience engineer from Production Engineer (PE) section. For my section, which
is production innovation (PI), the new line will be set up based on the process flow
provided.
3.1.2
For line 930 which is hybrid line, before we start to set up new line, we have to
investigate that the process flow done achieve the tact time requirement.
Unfortunately, we discover that the original process flow done is not achieved the
tact time (Refer to figure 3.1). In order to achieve the tact time, we have to re-edit
the process flow. Therefore, I had been given a task to brainstorming on how to
make the process flow fulfilled the tact time requirement. Tact time can be defined
as the time required by an operator in order to complete their job. For this new line,
the tact time requires was 30 seconds.
16
The current line which produced the same model have different line layout
with the new layout .There are many different things in this hybrid line compared to
current line which are quantity manpower, line layout and the target time for a
station.
The target time for current line is 15 seconds compared to hybrid line which
is 30 seconds. The first thing that we need to do is we need to make sure that we are
not observe the wrong station because even this new line will produce the same
product with current line but this new hybrid line have combined processes from
current process flow. Then we need to take the tact time value for a station based on
new process flow.
After getting all tact time data for all stations we need to summarize which
station have lower tact time and not logic for target time for a station. Then we had
discussed the action that will take for stations that we had done summarize it with
person in charge (PIC) which in charged for that line. We zoomed in the stations and
we study the processes again on that station to make sure that there is any change to
add some of the processes done by operator to the station involved. But, the process
must be from the neighbors station because the process done by operator is
continuously.
Observation
Refer line
balancing
Brainstorming
Discussion
Finish
18
20
21
CHAPTER 4
LINE SETUP
4.1
INTRODUCTION
To setup a new line, we have to understand the process flow of the line. The
schedule of line setup can be refer to figure 4.1. The line setup flow is:
Process flow
Line layout
Table setup
Material setup
Equipment setup
Buyoff
Operator entering
the line
Adjustment
Production
Improvement
22
4.2
PROCESS FLOW
During intern period in this department, the first task which given to me and
my partner is we need to study the process flow for a line. It is because different line
will have different process flow. The objective of this task is to make the trainee to
understand the process flow before involving in line setup process. Line Setup must
begin with the study of the process flow provided. The process flow provided must
be accurate since the line layout will be created based on the process flow.
23
4.3
ESS-04 LINE
ESS-04 line produced AD-5970H model. Actually there are 4 lines which
used the same process flow because produced the same model. ESS-04 line is a
hybrid line which means it is a line improved from current line which is ESS-01. So,
the first things while setup the line I need to study the process flow from the current
line. It is important for me because I must know how the processes done for all
stations before going to line layout. So, I will more understand about the line layout
without checking back how the processes going by a line.
24
4.3.1
LINE LAYOUT
LINE
02
: ESS
MODEL
5970XX
: AD-
25
The line layout was made based on process flow. We can design the line
layout easily if we already understand the process flow. After designing the line
layout, we must make sure that the line layout is suit with the process flow.
4.4
TABLE SETUP
After completing the first two stages, I was involved with my supervisor in line
setup planning. The objective of this activity is to minimize the complication happen
during setup the line. It is better to avoid it rather than facing it.
Start
Plan
Confirm
Start setup
the table
27
The things that we need to plan before preparing the table is we must know
the space required for the whole line. Then we marked the length and wide for a line
needed as a guide to others Production Innovation members.
1 compartment of floor tile = 61 cm (length)
4.4.1
Type of tables:-
29
30
The material required for a line is stands, accessories, bin, pen holder and etc. It is
important to prepare it before operator entering the line to avoid any problem
happen.
This part is prepared by other group which is Line Maintenance. They will prepare
all suitable machine needed in a line. Example of machine is skew adjustment
machine and
This process is done by Line Maintenance group. They will make sure that the
machines setup in a line is in good condition or not. They are also will test the
machine to make sure it is functioning well. They will put a form after checking the
machine.
32
4.5.4 OPERATOR ENTERING THE LINE
After completing all important stage, the operators will entering the line and their
supervisor will arrange them in their own station. Operator will report the missing
items and problems facing when they test this new line. Refer to Figure 4.5.4 for
checklist missing items. Besides that, the operators need to check whether they feel
comfortable in their station because only the operator knows about their station. It is
because it will affect their capability while doing their process. They will spend 10
hours a day in a line so it is important to make sure that they will do their job easily
without any problem.
4.5.5 ADJUSTMENT
If there are issues after operator entering the line, the person in charge must make
sure that the issues must be solved as soon as possible.
4.5.6 PRODUCTION
After adjusting the line, the operator will remain on that line until the line remove.
Different line will have different target of output. The target of output is depending
on the target time for a station.
33
4.5.7 IMPROVEMENT
Start
Take
handling time
Take machine
time
Record
Finish
The handling time and machine time is different. Some stations do not
have machine so that the process done is handling. We need to take when the
operator start the process until he/she finish. For example the process done by
operator is tighten top cover. So we need to take the load and unload top cover and
tighten process.
34
If the station have machine so we need to consider the machine time. Some station
which having machine, the operator done other process while waiting for the
machine finish the process. If the process which is more to handling is more that
machine time, we need to take handling time to record in line balancing data. It is
same if the handling time is less than machine time, the data will be machine time.
machine or jig for a station. If the tact time we recorded is for station which having
two machine, we need to divide the tact time value with two.
35.
Based on line balancing above Figure 4.5.8, the information that we can
get is which station has showed the highest tact time. Then we must make sure that it
is exceeds the target time or not. The words referred to this highest tact time value is
bottleneck. After knowing the bottleneck process, we need to prepare Compiled
Standard Operation Chart (CSOC) at Figure 4.5.8.1. We can divide the process done
by operator by using this chart and we can know which minor process for a station
have high tact time.
Figure 4.5.8.1
After that, we need to do Cause and Effect Diagram (Figure 4.8.2). It is also known
as Ishikawa or Fishbone diagram. Fishbone diagram is a tool from seven tool of
Total Quality Management (TQM) that identifies potential sources of process
variation that may affect an outcome.
36
Cause
Materials
Methods
Effect
Manpower
Machinery
TRV-11
Process: - Screwing TRV Cover to TRV Chasis Assy.
: - Install insulator to TRV Chasis Assy.
Problem (s) :- nejico problem
~got high tact time because need to screw at 6
points.
:- there are 3 times to pick up the material before
37
The other things that will be focused on are about Muda. Muda is a
Japanese word which means waste. The example of waste is movement waste can
be refer to Figure 4.4.8.3.
38
39
CHAPTER 5
SELF-ACTIVITIES
5.1
Karakuri is a Japanese word which mean a equipment that will make the
operator can do his/her process easily. This karakuri used Programmable Logic
Controller (PLC) to function. A PLC or programmable controller is a digital
computer used for automation of electromechanical processes, such as control of
machinery on factory assembly lines, amusement rides, or light fixtures. PLCs are
used in many industries and machines. Unlike general-purpose computers, the PLC
is designed for multiple inputs and output arrangements, extended temperature
ranges, immunity to electrical noise, and resistance to vibration and impact. A PLC
is an example of a hard real time system since output results must be produced in
response to input conditions within a bounded time.
Power
supply
PLC box
Figure 5.1.1
40
Figure 5.1.2
There are two sides at PLC box. The input side will be on the right of the
PLC box and the number will start with 0000, 0001, 0002, , etc. Besides, the
output side will be on the left side and the number with start with 500, 501, 502, ,
etc.
From the observation of slide guide shaft karakuri, there are seven input and
four output. The input wire is consists of sensor wire, switch wire and etc. We used
blue wires as indicator. Then for output side, we used white wires. We cannot used
green wires because it will bring to different meaning which is ground.
* Connected to 24V DC
at PLC box
* Connected to 0V at
PLC box
* Connected to switch
Figure 5.1.3
41
Figure 5.1.4
Based on figure above, we can see that the sensor wire have three different
colors of wire which are black, blue and brown. These different colors have different
meaning. The black wire is means output wire but when we connected into PLC, it
will be input because sensor is input side of PLC. Then, the blue wire is means
ground and lastly brown wire is means power.
After we connected all the wire involved, we will understand the function of
input and output wire. The software that will be used in this project is Ladder
Diagram Builder. We can build ladder diagram by using this software. This software
will be transferred to PLC box.
.
42
5.2
5.2.1
INTRODUCTION
One of the project that I had completed is stopper platen on rail. This stopper platen
will be implementing for SMI. The stopper platen used 1 relay, 1 sensor , 1 solenoid
valve , 1 plunger and 1 power supply. The sensor that we used was photosensor.
5.2.2
PHOTOSENSOR
5.2.3
RELAY
A relay is an electrically operated switch. Relay consists of two part which is and
coil contact.Contact will activated when the coil is energize. Relays allow one
circuit to switch a second circuit which can be completely separate from the first.
Relay was used for this project because it can switch high voltages and it is better
choice for switching large currents (> 5A). Refer to figure below for circuit diagram.
Figure 5.2.3
The sensor will detect the platen passed on rail. When the sensor detects the
platen, the plunger will advance. Therefore, the next platen will stop. On the other
hand, when the sensor do not detect any platen, the plunger will retract and the
platen will passed the plunger. This project had succeeded. Thanks to all my
teamwork for their guidance.
44
CHAPTER 6
DISCUSSION
The main objective of this program is to integrate theory with practical. Lack
of practical knowledge is one the deficiency that need to be overcome by a workerto-be, thus would be said that this training is somewhat good enough for student to
at least gain an industrial experiences.
CHAPTER 7
RECOMMENDATION
7.1
In order for the next candidates to gain better knowledge and experience of
working environment from the Industrial Internship Program, the author would like
to strongly suggest some recommendations to be reviewed by industry unit of IIUM
In SONY, there is no specific PIC that will guide the internship student for
each job. Thus, trainee faced difficulty to do their work and sometime they
didnt know what they have to do next after they had completed their task. If
Sony provide PIC to train them, there will be a lot easier since the PIC will guide
and assist us whenever we face confusing and difficulty. Therefore, the
internship student will not feel neglected.
47
7.2
The fact that the author has finished her 12 weeks internship period
successfully is enough proof that the unit has done its role very well for
student industrial internship realizable and successful ever semester. However, the
author strongly feels that there are some points that are on need of improvement by
the unit and the university which would be better facilitate the needs of the students
and the host company as well.
7.2.1
48
CHAPTER 8
CONCLUSION
The author has completed the Industrial Internship Program at Sony EMCS
(M) Sdn. Bhd. Generally the purpose of the program is to expose trainee to the
world of work so that the trainee can relate theoretical knowledge with application
in industry. During training, the author was attached at the Manufacturing
Engineering(ME) under supervision of Mr. Suhaizi. The author has learned and
understands a lot of things about the electrical maintenance tasks and works.
Moreover, the training program was not only beneficial for the author in term
of technical or academic base but the author could also develop various skills. From
the training program, the author had developed skills in work ethics, communication
and management skills, enhancing her leadership skills etc. Since there are different
levels of personnel, the author had experience in adapting to this kind of
environment.
The host company, Sony also gave a full cooperation and has provided a
good training and experience to the author. All the knowledge and experiences
gained by the author is a result of good cooperation and strong support from Sonys
staffs to the author to achieve his goal to be a well rounded person and a good leader
with motivational and high personal skills.
49
The Industrial Internship Program is a good and successful program. The
author also feels real proud to undergo industrial internship training at Sony and to
be a member of Production Innovation. The author really appreciates the time that
has been spent during the training at Sony EMCS (M) Sdn. Bhd.
50
CHAPTER 9
APPENDICES
Stopper Platen On Rail Project
Power Supply
Relay
51
Solenoid Valve
Plunger
52