gmi practical report

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Industrial In-Plant Training Report at Active Precision Sdn Bhd 1.0 INTRODUCTION 1.1 INDUSTRIAL IN-PLANT TRAINING The Engineering discipline is practical in nature and mainly hinged on experience. Hence, there is great need for any student aspiring to be a professional engineer to have some form of work experience while studying at school, in a reputable engineering firm related to his/her course of study. Students Industrial In-Plant Training Scheme is in accordance with the higher education policy of technical education to enable students to expose to the working experience in industries and to enable them to be useful to their employers practically and not theoretically alone. The Students Industrial In-Plant Training Scheme gives students the opportunity to gain some relevant experience before leaving the campus. The experience gotten by the students during the In-Plant program would enable them quickly fit into the industry upon graduation. I had my Industrial In-Plant Training work experience at the Active Precision Sdn Bhd (ACTIVE), a precision tooling company, and an indigenous engineering firm. At ACTIVE, I have learnt the fundamentals of Mechanical engineering; Computer Aided Design (CAD), Solid Works, and other relevant software such as Computer Aided Manufacturing software (CAM), Unigraphics, and AutoCAD (2D design software). My daily activities at ACTIVE recorded in the GMI logbook. 1.2 AIM The Students’ Industrial Training Scheme (In-Plant) is aim at giving students the opportunity to have work experience and practically apply the theoretical concepts learnt in the Institute. It is also aims at widening the mental and creative horizon of the students.

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Industrial In-Plant Training Report at Active Precision Sdn Bhd1.0INTRODUCTION 1.1 INDUSTRIAL IN-PLANT TRAININGThe Engineering discipline is practical in nature and mainly hinged on experience. Hence, there is great need for any student aspiring to be a professional engineer to have some form of work experience while studying at school, in a reputable engineering firm related to his/her course of study. Students Industrial In-Plant Training Scheme is in accordance with the higher education

TRANSCRIPT

Page 1: GMI Practical Report

Industrial In-Plant Training Report at Active Precision Sdn Bhd

1.0 INTRODUCTION

1.1 INDUSTRIAL IN-PLANT TRAINING

The Engineering discipline is practical in nature and mainly hinged on

experience. Hence, there is great need for any student aspiring to be a

professional engineer to have some form of work experience while studying at

school, in a reputable engineering firm related to his/her course of study.

Students Industrial In-Plant Training Scheme is in accordance with the higher

education policy of technical education to enable students to expose to the

working experience in industries and to enable them to be useful to their

employers practically and not theoretically alone.

The Students Industrial In-Plant Training Scheme gives students the

opportunity to gain some relevant experience before leaving the campus. The

experience gotten by the students during the In-Plant program would enable

them quickly fit into the industry upon graduation.

I had my Industrial In-Plant Training work experience at the Active

Precision Sdn Bhd (ACTIVE), a precision tooling company, and an indigenous

engineering firm. At ACTIVE, I have learnt the fundamentals of Mechanical

engineering; Computer Aided Design (CAD), Solid Works, and other relevant

software such as Computer Aided Manufacturing software (CAM),

Unigraphics, and AutoCAD (2D design software). My daily activities at

ACTIVE recorded in the GMI logbook.

1.2 AIM

The Students’ Industrial Training Scheme (In-Plant) is aim at giving students

the opportunity to have work experience and practically apply the theoretical

concepts learnt in the Institute. It is also aims at widening the mental and

creative horizon of the students.

Page 2: GMI Practical Report

Industrial In-Plant Training Report at Active Precision Sdn Bhd

2.0 IN PLANT WORKPLACE

Description of workplace:

NAME: ACTIVE PRECISION SDN BHD

ADDRESS: NO 2, JALAN LOMBONG EMAS 2, SEREMBAN LIGHT

INDUSTRIAL PARK, 70200, SEREMBAN,

Plant Training Report at Active Precision Sdn Bhd

IN PLANT WORKPLACE

Figure 1: Active Precision (HQ)

ACTIVE PRECISION SDN BHD

NO 2, JALAN LOMBONG EMAS 2, SEREMBAN LIGHT

INDUSTRIAL PARK, 70200, SEREMBAN,

NO 2, JALAN LOMBONG EMAS 2, SEREMBAN LIGHT

Page 3: GMI Practical Report

Industrial In-Plant Training Report at Active Precision Sdn Bhd

2.1 ACTIVE’s BRIFE HISTORY

Active Precision Sdn Bhd (ACTIVE) is Negeri Sembilan’s premier indigenous

engineering company. It was establish on the year 1993 and Commercial

business started in August 1995. ACTIVE fully owned by Mr Pathma, (MD of

Active) providing efficient and reliable engineering base for the entire

semiconductor, fabrication, and oil and gas industry.

Currently ACTIVE is serving for various multinational companies such

as Matsushita Group, Sony Group, Epson (M), Hitachi, Western Digital, Seiko

Instrument, Sun Power, Smart Modular, etc. We have enclosed details of the

company, which would provide you an overview of our company. We

confidently hope that our services would meet your requirements of any sort.

Our record of accomplishment on services and price has been very much of a

hand for the companies we serve.

The company also supplies the components in sub assembly condition.

In addition, an efficient team of talented technocrats strengthens us and a

well-equipped manufacturing plant outfitted with advanced technology

machinery imported from techno-rich countries like Japan, Germany, Korea

and USA.

Active’s motivation, drive, and target embedded in its vision and mission

statements thus:

Vision

“To be a world class Engineering Company.”

Mission

“Provide world class engineering services in recognize Malaysia’s and

International companies.”

� Figure 2: ACTIVE logo

Page 4: GMI Practical Report

Industrial In-Plant Training Report at Active Precision Sdn Bhd

2.1.1 Quality Policy

“To satisfy and strive to exceed customer requirements and achieving highest

customer satisfaction in Cost, Quality and Time at all time with active

participation of all employees”.

Active Precision manufactures Precision Tooling- Tool & Die, Mould, and Jigs

& Fixture, to cater for a wide range of industrial applications.

ACTIVE’ intention is to deliver Precision Tooling and internationally through

meeting customer requirement and achieving highest customers’ satisfactions

in Cost, Quality, and Time at all times.

The management is committed to operate an effective quality management

system meeting the requirement of ISO 9001:2000 and ensure its

commitment at all levels of employees within its organization.

The quality objectives outlined are being monitor and review periodically to

indicate the actual performances of the Cost, Quality, and Time. Active will

continually strive to identify weak areas and improve its performance in order

to enhance their capabilities to consistently meet and exceed their customer’s

expectations.

Foreign engineers who have been train locally and abroad on live projects

and in all engineering disciplines manage ACTIVE. It is fully equipped to

provide its services in all areas of the precision tooling manufacturing.

Page 5: GMI Practical Report

Industrial In-Plant Training Report at Active Precision Sdn Bhd

2.1.2 Environmental Policy

“To be acquainted with applicable legal and other requirements, to minimize

the creation of waste and pollution with active participation of all employees”.

Active Precision manufactures Precision Tooling

& Fixture, to cater for a wide range of industrial applications.

ACTIVE’ Environmental Policy is to be a responsible corporate citizen in

protecting the environment. ACTIVE are committed to complying with

accepted environmental practices, including the commitment to meet or

exceed applicable legal and other requirements, to strive for continual

improvement in their environmental management system, and materials and

their people in order to reduce the environmental impacts associated with

their work.

ACTIVE pledges to implement

further enhance environmental performances. Their main objectives and

targets are,

� Investigate the reduction of schedule wastes

� Reduce, reuse or recycle generated scheduled wastes

� Improve the storage efficiency of sch

spills/leaks

This Environmental Policy will be communicated to all personals working for

or behalf of ACTIVE and available to the public.

� Figure

Plant Training Report at Active Precision Sdn Bhd

Environmental Policy

“To be acquainted with applicable legal and other requirements, to minimize

the creation of waste and pollution with active participation of all employees”.

Active Precision manufactures Precision Tooling- Tool & Die, Mould, and Jigs

or a wide range of industrial applications.

ACTIVE’ Environmental Policy is to be a responsible corporate citizen in

protecting the environment. ACTIVE are committed to complying with

accepted environmental practices, including the commitment to meet or

ceed applicable legal and other requirements, to strive for continual

improvement in their environmental management system, and materials and

their people in order to reduce the environmental impacts associated with

ACTIVE pledges to implement and operate the ISO 14001:2004

further enhance environmental performances. Their main objectives and

Investigate the reduction of schedule wastes

Reduce, reuse or recycle generated scheduled wastes

Improve the storage efficiency of scheduled wastes without

This Environmental Policy will be communicated to all personals working for

and available to the public.

Figure 3: ISO Certification

“To be acquainted with applicable legal and other requirements, to minimize

the creation of waste and pollution with active participation of all employees”.

Tool & Die, Mould, and Jigs

ACTIVE’ Environmental Policy is to be a responsible corporate citizen in

protecting the environment. ACTIVE are committed to complying with

accepted environmental practices, including the commitment to meet or

ceed applicable legal and other requirements, to strive for continual

improvement in their environmental management system, and materials and

their people in order to reduce the environmental impacts associated with

EMS to

further enhance environmental performances. Their main objectives and

eduled wastes without

This Environmental Policy will be communicated to all personals working for

Page 6: GMI Practical Report

Industrial In-Plant Training Report at Active Precision Sdn Bhd

2.2 ACTIVE’s SERVICES

ACTIVE’s core services include the following:

• Manufacturing (Precision Component)

• Jigs & Fixtures

• Tools & Dies

• Moulds

• Project Management (Automation)

• Conceptual Engineering design

In order to create a conducive environment, ACTIVE has established one of

the most equipped engineering tool room in Seremban with the latest in

Engineering Equipments, Machines, Software, Project Management,

Administrative, Finance and Accounting software (UBS).

The company library is up-to-date with books on Engineering, Accounting,

Management, and all other disciplines relevant to its operations. It is also

equipped with Mechanical Engineering Literature, Drawings and

Documentation. It has Internet connection to a worldwide web for additional

engineering information and communication.

Page 7: GMI Practical Report

Industrial In-Plant Training Report at Active Precision Sdn Bhd

2.3 ACTIVE’s ORGANIZATIONAL STRUCTURE

Specific department undertakes all of ACTIVE’s activities, which can be

dividing into two major categories namely:

• Administration: -

This comprises of the non-technical departments.

• Production: -

Comprises of the technical departments.

Chart 1 shows a diagrammatic representation of the organisational structure

of ACTIVE.

Page 8: GMI Practical Report

Industrial In-Plant Training Report at Active Precision Sdn Bhd

MOT 091005 GERMAN MALAYSIAN INSTITUTE 8

MANAGING DIRECTOR

EXECUTIVE DIRECTOR, (ADMINISTRATION)

EXECUTIVE DIRECTOR, (PRODUCTION)

LEGAL ADVISER

QA/QC Department

CHART 1: ACTIVE’s ORGANIZATION CHART

Engineering Department

Sales Department

Administration Department

Human Resource

Department Manufacturing Department

Page 9: GMI Practical Report

Industrial In-Plant Training Report at Active Precision Sdn Bhd

MOT 091005 GERMAN MALAYSIAN INSTITUTE 9

2.3.1 ACTIVE’s Departments

The various departments in ACTIVE and their functions with respect to project

execution are:

Non-Technical Departments:

• Finance and Accounts:

-Treasury management, billings, accounting and financial management.

• Administration and Personnel:

-Harnesses human and material resources and set out ways of utilizing

them in order to maximize profit. General administration and personnel

management.

• Business Development:

-Sourcing for business via bids or otherwise to ensure company growth.

• Public Affairs:

-Projecting and sustaining a favourable image for the company.

• Company secretariat/Legal Services:

-Providing legal insurance and board secretarial services.

Page 10: GMI Practical Report

Industrial In-Plant Training Report at Active Precision Sdn Bhd

MOT 091005 GERMAN MALAYSIAN INSTITUTE 10

Technical Departments

• Engineering:

-It is the heart of ACTIVE. Preparation of engineering design and studies.

• Production:

-Organize/arrange staff development programs like on-the-job-training,

short-term courses and seminars, overseas rotational training etc, to

ensure that ACTIVE’s personnel are inform of technological advancement

in the industry. It ensures employee development.

• Manufacturing:

- Manufactures various precision parts, as per the customer’ drawing.

• Fabrication:

-Management of fabricating activities.

• Projects:

-Co-ordinates the engineering activities are undertake during any project

including arranging for site visits, liaison with the customers to inform them

about the progress of their projects. Manage of all capital projects.

• Project Controls:

-Project planning and scheduling, cost estimating, cost engineering and

information technology.

• Quality Assurance/ Control:

-Ensures compliance with company quality standards.

Page 11: GMI Practical Report

Industrial In-Plant Training Report at Active Precision Sdn Bhd

MOT 091005 GERMAN MALAYSIAN INSTITUTE 11

2.4 ACTIVE’s EXPERIENCE

Since its inception, ACTIVE has executed over hundreds of projects of varying

magnitude and cost implications in past one year. Among those projects when I

was around are:

• Seiko Instrumentation, over 5 year’s Precision Tooling and Spare Parts

service.

• Scomi Rail, Fabricate Skid (radiator), exported parts.

• Western Digital, over 7 years Precision Tooling services

• Sun Power, Design, Manufacture, and Fabricate parts – which I met on

ground.

• Ceram Tech, jiggering machine overhaul (Automation) - which I met on

ground.

• Link Tech, Design, and Fabricate Generator - which I met on ground.

• Hitachi, 3T/4T Mould (Repair) - which I met on ground.

• Hitachi, Profan Mould (Maintenance) - which I met on ground.

Page 12: GMI Practical Report

Industrial In-Plant Training Report at Active Precision Sdn Bhd

MOT 091005 GERMAN MALAYSIAN INSTITUTE 12

3.0 PROJECT EXECUTION IN ACTIVE

3.1 LOGBOOK

Every single task or activity has recorded in the logbook on daily basis. The

Supervisor on monthly basis were also reviewing the logbook where his

comments and technical advice per-training to the job done for the month given

to me for improvement for the followings’ tasks.

Below are the highlights of major achievement, which recorded in the logbook:

���� Service and repair the following moulds:

� Profan (HITACHI)

� 3T/4T Mould (HITACHI)

���� Manufacture Precision Tooling Parts:

� Lever HDS Bias

� Mounting Bracket

� ‘L’ Jig

� Wafer storage

� Extruder Die

� Ramp MDW Everest

� Set Up Gauge Block

� Singulation Plate

� Ram Pin Guide

� Indexing Finger

� Bracket Plate

� Toggle Plate

� Flag

� J Shoe

� Etc.

Page 13: GMI Practical Report

Industrial In-Plant Training Report at Active Precision Sdn Bhd

MOT 091005 GERMAN MALAYSIAN INSTITUTE 13

���� Manufacture Assembly Parts (Mass Production)

� Locating Jig

� PVC Elbow

� Wafer Storage

���� Own Conceptual Designing

� Power Generator

� Slot Block

� Bracket

� Dispensing Hanger

� Aluminum Manifold

���� Documentation

� Site visiting reports

� Create mould defection report

� Amends Company Profile

���� Designing and Drawing Production

� Sketching of the product

� Design solid modeling.

� Create assembly drawing.

� CAD (SolidWorks software)

� CAM programming (UNIGRAPHICS software)

Page 14: GMI Practical Report

Industrial In-Plant Training Report at Active Precision Sdn Bhd

MOT 091005 GERMAN MALAYSIAN INSTITUTE 14

3.1.1 SELF-ASSESSMENT

Production Technology,

German Malaysian Institute. Self-assessment of Industrial Training

1. Name of Trainee: Lukshman Rao

2. Name and address of Active Precision Sdn Bhd,

Company Seremban Light Industrial Park, Seremban.

3. Guide from Industry Mr Pathman

(With designation) Production Manager

4. Date of Commencement 03 January 2011

Of Industrial Training

5. Number of day is present 84 days out of 84 days.

6. I hereby declare that, I have learnt following skills during my Industrial

Training:

No. Description Weightage

(%)

1 Learning new Techniques – Software, Machines, Process etc. 20

2 Part designing, Assembly of parts components, Drawings 10

3 Mechanical designing, Assembly and Fabrication 20

4 Calibration, Testing, Servicing and Repairing 5

5 Installation / Commissioning 5

6 Research and Development 5

7 Quality Control, Inspection 10

8 Housekeeping, Maintenances 5

9 Site Visiting / Meeting with customers/end users 10

10 Purchase and Marketing 2

11 Documentation 5

12 Any other (Specify)- Transporter/Dispatcher 3

Total 100

Date: Signature of Student

Page 15: GMI Practical Report

Industrial In-Plant Training Report at Active Precision Sdn Bhd

MOT 091005 GERMAN MALAYSIAN INSTITUTE 15

3.2 PROJECT INITILIZATION

ACTIVE’s business starts in the Business Development department when it

receives invitations from prospective clients to submit competitive

bids/quotations for executing projects. Relevant departments meet to decide

whether the decision is worthwhile. A project manager is appointing to

coordinate the preparation of the bid. This usually involves most of the

departments. Finally, the Business Development department submits the

proposal and follows it up.

If the bid is successful, ACTIVE management appoints from various

departments a Project Manager and other personnel that will form the project

team.

The Project Manager maintains a harmonious relationship with the client and

ensures that his personnel have the right facilities and a conductive working

environment to execute the project.

The Finance and Accounts department prepares invoices and collects

payments from clients. This helps to maintain a positive cash flow and to

ensure that funds are available for the payment of wages and other corporate

expenses.

A typical project team usually comprises mainly of personnel from the

Production department.

Page 16: GMI Practical Report

Industrial In-Plant Training Report at Active Precision Sdn Bhd

MOT 091005 GERMAN MALAYSIAN INSTITUTE 16

4.0 THE PRODUCTION DEPARTMENT

4.1 INTRODUCTION

Usually, a typical project begins in the process group with the conceptual or

basic design. The process group develops the initial part drawings, evaluates

all the options, and proposes the best alternative for the manufacturing. Other

disciplines will then work on what the process group has put down.

4.2 PRODUCTION DEPARTMENT

The Production department is the ‘engine room’ of ACTIVE’s operations. The

department is directly involved in the execution of jobs and on whose

shoulders the responsibility of meeting client’s specification, quality, work

procedure, standards and schedule rests.

The department is dividing into discipline groups. A manager, who reports to

the Executive Director Operations, is Head of the Engineering Department. A

team of Engineers of the various discipline groups fulfils the role of the

department. An Engineer who is more knowledgeable in the activities of the

group leads each of the discipline groups.

During the training, I was attached to the Manufacturing and Engineering

discipline group which is under the Production department.

Figure 2 shows the organizational structure for the Production department.

4.3 ROLES OF THE PRODUCTION DEPARTMENT

On any project, the Production department is concerned with the following:

���� To cultivates the manufacturing quality.

���� To ensures that the manufacturing sector is equipped with maximum

facilities.

���� To develop manufacturing sector that is reliable, economical and

operationally flexible.

Page 17: GMI Practical Report

Industrial In-Plant Training Report at Active Precision Sdn Bhd

MOT 091005 GERMAN MALAYSIAN INSTITUTE 17

PRODUCTION MANAGER

LEAD, MANUFACTURING

LEAD, ENGINEERING

ENGINEERING GROUP

LEAD, ELECRICAL

MANUFACTURING GROUP

ELECTRICAL GROUP

ASSISTANCE MANAGER

CHART 2: ORGANIZATIONAL STRUCTURE OF THE PRODUCTION DEPARTMENT

Page 18: GMI Practical Report

Industrial In-Plant Training Report at Active Precision Sdn Bhd

MOT 091005 GERMAN MALAYSIAN INSTITUTE 18

4.4 MANUFACTURING GROUP ACTIVITIES

To achieve the above objectives, the manufacturing group usually carries out the following

activities:

� Develop designing criteria.

� Formulate complete parts and assembly drawings.

� Prepare material requisition (MR) and Bill of Quantities (BOQ) for assembly drawing

� Create a process plan for each part.

� Analyse machine/equipment needed.

� Separate the drawings based on process involved

� Carry on with manufacturing processes.

� Send to QA/QC department.

4.5 MANUFACTURING GROUP DELIVERABLES

Deliverables are documents produced by a group with respect to the scope of the project. The

deliverables produced by the manufacturing group are -

� Conceptual Designing

� Assembly drawings

- Exploded

- Detailed

- Notes

� Material Requisition (MR)

� Bill of Material (BOM)

� Drawing and part numbering

� Detail Dimension Drawing

- Complete dimensions

- Projection angle (top, front, side)

- Isometric view

- Detail drawings

- Tolerances specification

Page 19: GMI Practical Report

Industrial In-Plant Training Report at Active Precision Sdn Bhd

MOT 091005 GERMAN MALAYSIAN INSTITUTE 19

COMPUTER SOFTWARES used by the Manufacturing group are;

� SolidWorks (Designing)

� CATIA (Manufacturing)

� Unigraphics (Manufacturing)

� MasterCAM (Manufacturing)

� AutoCAD (2D Drawings)

� Microsoft Excel (Documentation)

� Microsoft Word (Documentation)

Page 20: GMI Practical Report

Industrial In-Plant Training Report at Active Precision Sdn Bhd

MOT 091005 GERMAN MALAYSIAN INSTITUTE 20

5.0 SKILLS & PRACTICES ACQUIRED

5.1 Knowledge Acquired

From the day one of my In Plant Training, I were attach to the Production

Department, which is relates to my core course. I was attach in both manufacturing and

engineering departments, which my mainly my tack covers all from conceptual

designing until manufacturing the parts/products.

I was in ACTIVE with my colleague, which is also from GMI. After two weeks of

performances, our Production Manager, Mr Pathma, instructed us to be an assistance

supervisor/ leader trainee in Manufacturing and Designing sector respectively. Our

tasks was unique, because we were an assistance at the same time we also design,

manufacture, and lead a team to accomplish a task on site.

Several tasks accomplished by me personally and of course some with the

advice of my supervisor. Those are involved in mould repair and maintenance,

manufacturing precision parts, designing, on site modification/assemblies, working in

clean room in Western Digital and Sun Power and involved in reports/documentation.

The major activities /task, which I lead or carry out personally in ACTIVE, are as

following,

Page 21: GMI Practical Report

Industrial In-Plant Training Report at Active Precision Sdn Bhd

MOT 091005 GERMAN MALAYSIAN INSTITUTE 21

� Repair and Service Moulds

-Split the mould

• Figure 4: Mould Splitting

a. Safely lift the mould by crane, 4 lifting points normally. Stand it on the

ground cushioned by wooden or rubber.

b. The mould must be place on two rails on a clean table with sufficient

space. Tools used must be in good condition and should include Allen

wrenches, aluminium pry bars, rubber mallet, duct tape, and some

containers.

Page 22: GMI Practical Report

Industrial In-Plant Training Report at Active Precision Sdn Bhd

MOT 091005 GERMAN MALAYSIAN INSTITUTE 22

c. Separate mould at parting line carefully and look for any visible damage. If

mould is damage, report it at once. Check for rust in core and cavity and

report it at once if found.

d. Have containers to put all the parts in and identify it with the proper job

number.

e. Check for core pins in Ejector Housing (at the bottom clamp plate) and

remove the core pins first.

f. Remove all necessary screws in the Ejector Housing and remove it.

g. Remove screws from the Ejector Plate and remove it.

h. Check if all pins are marked, if not mark as necessary.

i. Remove all pins and parts from Ejector Housing. Protect all fragile parts

and critical areas with duct tape.

j. Remove all water line jiffy-plugs

k. Remove all slides assemblies and protect all critical areas with tape or

carefully store in container.

l. Remove the Sprue bushing, hot sprue, or any hot runner system.

m. Remove all screws from cavity and core inserts and install two or four

longer screws in cavity and core. Then knock out cavity and core inserts

from mould base by hitting screws with a rubber, aluminium, or copper

mallet. BE CAREFUL NOT to knock insert out onto the bench or floor and

damage it.

n. Once the primary inserts removed, remove all sub-inserts, gate inserts,

core pins, etc. and protect all critical edges with tape or carefully store in

container.

o. Carefully clean all details with a clean, mild solvent and clean towels being

careful NOT to damage sharp edges, parting surfaces, shutoffs, or the

cavity finish.

p. Finally, store all inserts in such a way that the moulding surfaces protected

for the next working procedure and cannot be accidentally damage. Clean

and grease others to avoid rust and put in safe position.

Page 23: GMI Practical Report

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MOT 091005 GERMAN MALAYSIAN INSTITUTE 23

� Remove clogged material in cavity plate

a) Remove insert plate from cavity plate

b) Make sure remove o-ring before heat cavity plate

c) Heat cavity plate using burner approximately 10 minute

d) Gentle knock the plastic material using pin (smaller then runner diameter) and

mallet

e) Be careful NOT to damage, runner area by accidently knock cavity area.

• Figure 5: Material clogged and removed

Page 24: GMI Practical Report

Industrial In-Plant Training Report at Active Precision Sdn Bhd

MOT 091005

� Increase width of the runner

a) Rub cavity plate with polishing stone to remove burr and clean the cavity

plate using clean cloth

b) Clamp cavity plate in the CNC machine table using clamp kit

c) Mill runner wall per side 0.25mm using 5

runner maintain 5mm

d) Careful remove cavity plate from CNC machine, for next procedure

e) Polish runner area after machining using oil stone

f) Carefully clean cavity plate with a clean, mild solvent and clean

Plant Training Report at Active Precision Sdn Bhd

GERMAN MALAYSIAN INSTITUTE

24

Increase width of the runner

Rub cavity plate with polishing stone to remove burr and clean the cavity

plate using clean cloth

Clamp cavity plate in the CNC machine table using clamp kit

Mill runner wall per side 0.25mm using 5 degree angle cutter, depth of the

runner maintain 5mm

Careful remove cavity plate from CNC machine, for next procedure

Polish runner area after machining using oil stone

clean cavity plate with a clean, mild solvent and clean

• Figure 6: Machining (modification)

GERMAN MALAYSIAN INSTITUTE

Rub cavity plate with polishing stone to remove burr and clean the cavity

Clamp cavity plate in the CNC machine table using clamp kit

degree angle cutter, depth of the

Careful remove cavity plate from CNC machine, for next procedure

clean cavity plate with a clean, mild solvent and clean cloth

Page 25: GMI Practical Report

Industrial In-Plant Training Report at Active Precision Sdn Bhd

MOT 091005 GERMAN MALAYSIAN INSTITUTE 25

� Repair mould-flashing area

a) Indentify core insert depression area

b) Weld depression area, approximately 0.5 mm thickness

c) Rub cavity plate with polishing stone to remove burr and clean the cavity

plate using clean cloth

d) Clamp core insert plate in the grinding machine, grind flat to the surface

e) Remove core insert from grinding table for next procedure

f) Polish cavity finish area using oil stone

g) Carefully clean cavity plate with a clean, mild solvent and clean cloth

• Figure 7: Welding and Polish critical area

Page 26: GMI Practical Report

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MOT 091005 GERMAN MALAYSIAN INSTITUTE 26

� Mould Maintenance

a) Check ejector pins, guide pin ejection fully forward position. Ensure they

are not loose and free from galling on the rods.

b) Blow off water remained in the waterlines under high air pressure

c) Clean the mould surface with proper cleaning agent or blow the mould

with high air pressure

d) Grease regularly all un-self lubrication parts like guide bushes, angle

location plates or wear plates.

e) Spray antirust agent inside mould.

f) Check all identification plates whether they are legible, in position or not

g) Place the mould in planned location with good protection on all extending

parts.

Figure 8: Mould Maintenances

Page 27: GMI Practical Report

Industrial In-Plant Training Report at Active Precision Sdn Bhd

MOT 091005 GERMAN MALAYSIAN INSTITUTE 27

� Mould assembly

a) Procedure of assembly reverses that of disassembly of the mould.

b) Grease all un-self lubrication parts like guide bushes, Guide pins or wear

plates

c) Spray antirust agent inside mould surface.

• Figure 9: Completed and assembled mould

Page 28: GMI Practical Report

Industrial In-Plant Training Report at Active Precision Sdn Bhd

MOT 091005 GERMAN MALAYSIAN INSTITUTE 28

� Manufacturing Precision Parts

Part Name: Ramp, WDM, Everest-10D

Drawing No: 2963-703253-000-01P (Refer Appendix 1)

Material: 316 SST

Company: Western Digital (Malaysia)

Process Plan

� Squaring

� Grinding included w/cut allowance

� Drilling

� W/cut process

� Parting

� Hole and slot w/cut

� Profile cutting with polishing allowance

� 1st Polishing (hand polishing)

� Electro polishing

� 1st Inspection

� 2nd Polishing (gloss required areas)

� Final Inspection

• Figure 12: Part Inspection

• Figure 11: Hand Polishing

• Figure 10: Compares’ squaring and completed Part

Page 29: GMI Practical Report

Industrial In-Plant Training Report at Active Precision Sdn Bhd

MOT 091005 GERMAN MALAYSIAN INSTITUTE 29

Part Name: Set-Up Gage Block W/Pivot and W/O Pivot

Drawing No: 09-80743-00 (Refer Appendix 2-4)

Material: SST 440, 54-60 RC

Company: Western Digital (Malaysia)

Process Plan

� Squaring

� Drilling

� Hardening (54-60 RC)

� Grinding

� W/cut process

� Hole, Pocket and Slot w/cut

� Profile cutting with polishing allowance

� Polishing (hand polishing)

� Inspection

• Figure 13: Set Up Gage Blocks

• Figure 16: W/Cut Process

• Figure 15: Work Piece Setting

• Figure 14: Part before W/Cut Process

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MOT 091005

Part Name: Toggle for R16 M/C

Drawing No: R648-11710

Material: DF 2/SNC 22 (HRC 53)

Company: Seiko Instrument Technologies (Singapore)

Process Plan

� Squaring with grinding allowance

� Drilling

� Hardening (HRC 53)

� W/cut process

� Profile cutting

� Polishing (Sandpaper Machine)

� Grinding

� Inspection

• Figure 17: Toggle (J-Shoe)

Plant Training Report at Active Precision Sdn Bhd

GERMAN MALAYSIAN INSTITUTE

30

Toggle for R16 M/C

11710-LE-3 (Refer Appendix 5)

DF 2/SNC 22 (HRC 53)

Seiko Instrument Technologies (Singapore)

Squaring with grinding allowance

53)

Profile cutting

Polishing (Sandpaper Machine)

Shoe)

GERMAN MALAYSIAN INSTITUTE

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MOT 091005 GERMAN MALAYSIAN INSTITUTE 31

Part Name: Indexing Plate Finger for PC4 M/C

Drawing No: R648-2241-LE-3

Material: DF 2/SNC 22 (HRC 60)

Company: Seiko Instrument Technologies (Singapore)

Process Plan

� Squaring with grinding allowance

� Drilling

� Tapping (M5)

� Hardening (HRC 60)

� W/cut Process

� Profile cutting

� Polishing (Sandpaper Machine)

� Grinding

� Inspection

• Figure 18: Indexing Plate Finger

• Figure 19: Completed Part

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MOT 091005 GERMAN MALAYSIAN INSTITUTE 32

Part Name: ‘L’-Jig for Glass Storage

Drawing No: APSB/139/0311/00 (Refer Appendix 6)

Material: Derlin / POM

Company: AUO Sun Power (Malaysia)

Process Plan

� Raw Material Squaring

� CNC Profile Milling

� Steps, U/Cuts

� Radius

� Conventional Milling

� Groove

� Radius

� Drilling

� Deburring

� Inspection

• Figure 20: Complete assembled ‘L’ Jig

• Figure 21: Part Modelling

• Figure 22: During Machining

• Figure 23: Complete Machined Part

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MOT 091005 GERMAN MALAYSIAN INSTITUTE 33

Part Name: Extruder Die (806/7.5)

Drawing No: APSB/135/0311/00 (Refer Appendix 7)

Material: Aluminium

Company: Hoest Ceram Tec (Malaysia)

Process Plan

� Material Cutting

� Lathe Machine Process

� CNC Milling

� Boring

� Radius Profile Cutting

� Drilling

� C/boring

� Polishing

� Chamfering/Deburring

� Inspection

• Figure 24: Sample ‘Extruder Die’

• Figure 25: Part Simulation

• Figure 26: Lathe Machine Process

• Figure 27: CNC Milling Process

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MOT 091005 GERMAN MALAYSIAN INSTITUTE 34

� Manufacturing Assembly Parts (Mass Production)

Part Name: Locating Jig

Drawing No: APSB/XXX/1011/00 (Refer Appendix?)

Material: Polypropylene & Derlin

Company: AUO Sun Power (Malaysia)

General Process Plan

� Material Cutting

� Squaring Process

� CNC Milling

� Slotting

� Drilling

� C/boring

� Conventional Milling (Angle)

� Chamfering/Deburring

� Washing/Cleaning Process

� Assembly Process

� Inspection using actual part

• Figure 28: Locating Jig assembly stages

• Figure 29: Squaring Parts

• Figure 30: Tapping Process

• Figure 31: Washing Process

• Figure 32: Assembly Process

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MOT 091005 GERMAN MALAYSIAN INSTITUTE 35

Part Name: Wafer Storage Gen 4ASSY

Drawing No: SC-SPC-WT1-490-00 (Refer Appendix 8-11)

Material: T6 Aluminium

Company: AUO Sun Power (Malaysia)

General Process Plan

� Material Cutting

� Squaring Process

� CNC Milling

� Slotting

� Drilling

� C/boring

� Profile Milling

� W/Cut Process (Slots)

� Chamfering/Deburring

� Anodizing (Coating)

� Pin Grinding

� Assembly Process

� Brazing (Alz Welding)

� Inspection using actual part

• Figure 33: Wafer Storage

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MOT 091005 GERMAN MALAYSIAN INSTITUTE 36

Part Name: Pneumatic Vacuum for

Viking and Mars

Drawing No: APSB/009/0609 (refer appendix 12)

Material: T6 Aluminium, Pomulux SD

Company: Western Digital (Malaysia)

General Process Plan

� Modelling

� Test cut (different material)

� Material Cutting

� Squaring Process

� CNC Milling Process

� Slotting

� Drilling

� C/boring

� Profile Milling

� Chamfering/Deburring

� Alz Anodizing (Coating)

� Assembly Process

� Inspection using actual part

• Figure 34: Pneumatic Vacuum

• Figure 35: Pneumatic Tubing

• Figure 36: Mars Suction Part and Jig

• Figure 37: Viking Suction Part and Jig

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MOT 091005 GERMAN MALAYSIAN INSTITUTE 37

� Conceptual Designing

Part Name: Rail Grease Dispensing Hanger

Drawing No: APSB/135/0311/00 (Refer Appendix 13)

Material: Brass, Stainless Steel, PVC

Company: AUO Sun Power (Malaysia)

Tasks

� To modify the original ‘grease dispensing rail’ by adding two pressure grease

tank.

� Reduce the width of the rail holder/clamp.

� Reduce the total weight of the hanger.

� Change the current PVC clip size to smaller size.

• Figure 38: Grease Dispensing Rail

• Figure 39: Modification Modelling

Page 38: GMI Practical Report

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MOT 091005 GERMAN MALAYSIAN INSTITUTE 38

Part Name: Power Generator and Manifold

Drawing No: APSB/123/0111/00 (Refer Appendix 14&15)

Material: N/A

Company: Link Tech (Malaysia)

Tasks

� To create housing for new invented of 2 Phase Power Generator.

� Consist of two units of batteries, two output power switches, circuit breaker,

Voltage reader, Ampere reader, vacuum suction fan.

� Top cover, label engraving.

� Foam sprays coating (blue).

� Urethane rubber base protector

• Figure 40: Power Generator

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MOT 091005 GERMAN MALAYSIAN INSTITUTE 39

� Machine Maintanances

Machine Name: CNC Wire Cut Machine

Model Name: SODICK AQ327L

Duration: Approx. 5-6 Hours

Task Carried

� Clean the machine exterior and filters

� Clean the conductivity piece (top & bottom)

� Deionizer liquid maintenance

� Clean upper & lower wire guide

� Clean all the metal dust in the machine

� Add deionizer resin

� Set wire straightness

• Figure 41: SODICK Wire Cut Machine

• Figure 42: Before Cleaning Started

� Figure 43: After Cleaning Process Completed

• Figure 44: Conductivity piece

• Figure 45: Soaked in K-12 acid

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MOT 091005 GERMAN MALAYSIAN INSTITUTE 40

Machine Name: CNC Vertical Milling Machine

Model Name: Quick Tech VMC 1070

Duration: Approx. 3 Hours

Task Carried

� Clean the machine exterior and filters

� Clean machine’s scrap tray (inside machine)

� Clean the scrap drain

� Wash machine interior (using coolant)

� Drain the coolant sludge and add new coolant

� Release tool changer pressure

� Add hydraulic/slide way oil

� Clean the filter and dust in machine power box.

Figure 46: CNC Vertical Milling Machine

• Figure 47: Air pressure control unit

� Figure 48: Hydraulic oil tank

• Figure 49: Machine Control Box

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MOT 091005 GERMAN MALAYSIAN INSTITUTE 41

� Site Work

Machine: Twin Jiggering Machine

Company Name: Hoest Ceram Tech

Duration: 3 Weeks

Task Carried

� Relocate the machine to Site Work Place

� Disassemble the machine components (note all the parts)

� Clean the machine parts

� Modification takes place

� Fabrication process

� Assembly process

� Test run and construct an report

� Relocate the machine to its original place

� Final test run

• Figure 50: Machine relocation

• Figure 51: On site Work Place

• Figure 52: Moving the Machine

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MOT 091005 GERMAN MALAYSIAN INSTITUTE 42

Machine: Jiggering Machine

Company Name: Hoest Ceram Tech

Duration: 2 Months

Task Carried

� Clean the machine exterior and interior

� Disassemble the machine components (note all the parts)

� Clean the machine parts using kerosene

� Replace the cams

� Replace the guide shaft

� Fabrication process

� Assembly process

� Welding process

� Test run the machine

� Oven coating the machine body

� Cover assembly process

� Final test run

• Figure 55: After complete (In-House)

• Figure 54: At customers’ Plant

• Figure 53: Jiggering Machine

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MOT 091005 GERMAN MALAYSIAN INSTITUTE 43

� House-Kepping

Task Carried

� Done by daily basis

� 15 minutes Before and after work

� Noted duties carried out

� Clear the rubbish bin once filled

� Vacuum the dust around the production floor

� Clean air-cond filter

� Update notice whiteboard

• Figure 56: Production floor cleaning

• Figure 57: Machine Cleaning

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MOT 091005 GERMAN MALAYSIAN INSTITUTE 44

RECOMMENDATIONS

It is important that every level of worker in the company be able to do their job fully.

Delays due to numerous consulting of higher members of the company reduce the

effect of the workforce hired. Unskilled labourers been hired by the company make

errors. This also produces time delays and costly mistakes, which would require the

skills of a higher ranked employee of the company. This causes a chain of time

consuming that ripples through the workforce to a certain extent. The employees follow

not all safety regulations. This leads to risk of mishaps and serious injuries to

employees.

CONCLUSION

The Industrial In-Plant Training has positively contributed to my training as a future

Mechanical Engineer. At the In-Plant workplace (i.e. ACTIVE), I was able to reconcile

theoretical principles learnt in school with real Mechanical engineering design practice. I

also learnt various software applications relating to my discipline such as AutoCAD,

Solid Works, Unigraphics, Master Cam, CATIA, Microsoft EXCEL, Microsoft Word, etc.

Furthermore, I received extensive training on conceptual design fundamentals that

included from part design until assembly design. IN-Plant also gave me the opportunity

to learn about good work ethics, good interpersonal and communication skills.

The time spent on all the sites increased my knowledge of the industry in practical

sense and thus gives me the confidence to be certain of the future growth of my skills

and knowledge of the industry.

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MOT 091005 GERMAN MALAYSIAN INSTITUTE 45

REFERENCES

� Active Precision Sdn Bhd, Company Profile.

� Mr.Rahman, Institute based supervisor, German Malaysian Institute.

� Standard Industrial Report Format, GMI library.

� Chevron Corporation Training Manual (1996), Vol 1 & 2.