FACULTY OF INNOVATIVE DESIGN AND TECHNOLOGY

INDUSTRIAL VISIT REPORT

DMS 1053 (PRODUCTION MANAGEMENT)
GROUP 3

LECTURER NAME : PUAN LIANA BINTI YUSOF

STUDENT NAME
MUHAMMAD SYUKRY BIN KAMARUDIN

MATRIC NO.
038977

FARIS SYAZWAN BIN IZANI

039514

MOHAMMAD HAZMAN BIN JALALUDDIN

039302

PICTURE OF TEAM

Starting from left: Faris Syazwan,

Mohammad Hazman and Muhammad Syukry.

TABLE OF CONTENTS
No.
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2
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Contents
Introduction
Product Overview
Process Overview
Production Management
Question & Answers
Conclusion

Page
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9
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INTRODUCTION

We have visited 2 factories on 31 March 2016 until 2 April 2016 for our assignments which are :

1) NAME : SFCC CHEMICALS AND CASTINGS SDN.BHD

ADDRESS : NO. 13A, LORONG SANGGUL 1D, BANDAR PUTERI, 42100 KLANG, SELANGOR
DARUL EHSAN.
WEBSITE : www.sfcc.com.my
BACKGROUND : Has been develop first by Rajagopal and continued by his next generation.
Producing products based on casting processes and provide consultancy involved.

2) NAME : BERYLS CHOCOLATE CONFECTIONARY SDN BHD

ADDRESS : NO. 2, JALAN RAYA 7/1, KAWASAN PERINDUSTRIAN SERI KEMBANGAN, 43300
SERI KEMBANGAN, SELANGOR DARUL EHSAN.
WEBSITE : www.berylschocolate.com
BACKGROUND : Beryls Chocolate and Confectionery Sdn Bhd was created with
one single aim excellence. Since the company was established in 1995, our
focus has been on producing the very best chocolates for both the local and
global markets.

Their first factory was set up in 1995 in the small town of Desa Serdang located
at the southern zone of Kuala Lumpur. From humble beginnings, the company
started off by manufacturing consumer pack chocolates that were sold mainly
to duty free shops and supermarkets across the country. From there, they took
the first steps to establishing Beryls as a major regional chocolatier.

Shortly after that in 1998, they relocated and built their new factory in the Seri
Kembangan Industrial Area where they increased their production lines to
provide an even more diverse range of chocolate products to fulfil their
promise for high quality and delicious chocolates to their customers.

In 2008 and 2013, they opened up two more factories to keep up with the
growing demands from their customers as well as further develop new treats
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that their customers would love. The new factories helped expand their
capabilities to produce more than just consume r pack chocolates. Since then
they were able to produce chocolate for food service industries and move into
making cookies and other confectionery products.

Starting from their very first factory till today, Beryls Chocolate has since
become a well-loved consumer brand throughout the country and beyond.
Their products have been able to gain the recognition of discerning customers
from overseas and Beryls Chocolates can now be found in over 13 countries
around the world.

PRODUCT OVERVIEW
SFCC CHEMICALS AND CASTINGS SDN.BHD
The factory produce :

Boiler Spares And Packing

Foundry Chemical & Consumables

Ferrous & Non Ferrous Castings

Foundry Management & Consultancy

Spin Casting Machine And Furnace

Induction Furnaces Eletrotherm / Steadcast

Oven Industrial Oven

Contitherm Burners Gas And Oilfired

Heating Elements Mfg. And Supplies

Gravure Printing Rollers And Engraving

BERYLS CHOCOLATE CONFECTIONARY SDN.BHD

The factory produce :

DRAGEES
Tiramisu Series
Jar Series
Box Series
Tin Series
BAR
Camior Series
Fruity & Nuts Series
No Sugar Added Series
ASSORTMENTS
Mini Box Series
Crunchy Series
Fruity Series
Pikko Series
GIFT
Souvenir Series
Gift Series
COOKIES
Butter Cookies
Coconut Roll
Nougat
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PROCESS OVERVIEW
SFCC CHEMICALS AND CASTINGS SDN.BHD

SAND CASTING

Sand casting, also known as sand molded casting, is a metal casting process characterized by using
sand as the mold material. The term "sand casting" can also refer to an object produced via the sand
casting process. Sand castings are produced in specialized factories called foundries. Over 70% of all
metal castings are produced via sand casting process.
Sand casting is relatively cheap and sufficiently refractory even for steel foundry use. In addition to
the sand, a suitable bonding agent (usually clay) is mixed or occurs with the sand. The mixture is
moistened, typically with water, but sometimes with other substances, to develop the strength and
plasticity of the clay and to make the aggregate suitable for molding. The sand is typically contained
in a system of frames or mold boxes known as a flask. The mold cavities and gate system are created
by compacting the sand around models, or patterns, or carved directly into the sand.
The equipments needed in a sand casting process are:
1.
2.
3.
4.

Pattern
Mould box
Moulding sand
Crucible

There are six steps in this process:

1.
2.
3.
4.
5.
6.

Place a pattern in sand to create a mold.

Incorporate the pattern and sand in a gating system.
Remove the pattern.
Fill the mold cavity with molten metal.
Allow the metal to cool.
Break away the sand mold and remove the casting.

INDUCTION MELTING PROCESS

An induction melting is an electrical furnace in which the heat is applied by induction heating of
metal.Induction furnace capacities range from less than one kilogram to one hundred tonnes
capacity and are used to melt iron and steel, sand,copper, aluminium and precious metals.
The advantage of the induction furnace is a clean, energy-efficient and well-controllable melting
process compared to most other means of metal melting. Most modern foundries use this type of
furnace, and now also more iron foundries are replacing cupolas with induction furnaces to melt cast
iron, as the former emit lots of dust and other pollutants.

Since no arc or combustion is used, the temperature of the material is no higher than required to
melt it; this can prevent loss of valuable alloying elements.The one major drawback to induction
furnace usage in a foundry is the lack of refining capacity; charge materials must be clean of
oxidation products and of a known composition and some alloying elements may be lost due to
oxidation (and must be re-added to the melt).

INVESTMENT CASTING

Investment casting is an industrial process based on and also called lost-wax casting, one of the
oldest known metal-forming techniques. From 5,000 years ago, when beeswax formed the pattern,
to todays high-technology waxes, refractory materials and specialist alloys, the castings allow the
production of components with accuracy, repeatability, versatility and integrity in a variety of metals
and high-performance alloys. The fragile wax patterns must withstand forces encountered during
the mold making. Much of the wax used in investment casting can be reclaimed and reused.Lostfoam casting is a modern form of investment casting that eliminates certain steps in the process.

Investment casting requires the use of a metal die, wax, ceramic slurry, furnace, molten metal, and
any machines needed for sandblasting, cutting, or grinding. The process steps include the following:
1. Pattern creation - The wax patterns are typically injection molded into a metal die and are
formed as one piece. Cores may be used to form any internal features on the pattern. Several of
these patterns are attached to a central wax gating system (sprue, runners, and risers), to form a
tree-like assembly. The gating system forms the channels through which the molten metal will
flow to the mold cavity.
2. Mold creation - This "pattern tree" is dipped into a slurry of fine ceramic particles, coated with
more coarse particles, and then dried to form a ceramic shell around the patterns and gating
system. This process is repeated until the shell is thick enough to withstand the molten metal it
will encounter. The shell is then placed into an oven and the wax is melted out leaving a hollow
ceramic shell that acts as a one-piece mold, hence the name "lost wax" casting.
3. Pouring - The mold is preheated in a furnace to approximately 1000C (1832F) and the molten
metal is poured from a ladle into the gating system of the mold, filling the mold cavity. Pouring is
typically achieved manually under the force of gravity, but other methods such as vacuum or
pressure are sometimes used.
4. Cooling - After the mold has been filled, the molten metal is allowed to cool and solidify into the
shape of the final casting. Cooling time depends on the thickness of the part, thickness of the
mold, and the material used.
5. Casting removal - After the molten metal has cooled, the mold can be broken and the casting
removed. The ceramic mold is typically broken using water jets, but several other methods exist.
Once removed, the parts are separated from the gating system by either sawing or cold breaking
(using liquid nitrogen).
6. Finishing - Often times, finishing operations such as grinding or sandblasting are used to smooth
the part at the gates. Heat treatment is also sometimes used to harden the final part.

BERYLS CHOCOLATE CONFECTIONARY SDN.BHD

Starting from mix all the ingredients to make the chocolate-based.

Adding miscellaneous addition ingredients such as raisins, variety of nuts for delicious end
product that fulfill customers taste so that they happy and repeat order.
They do finishing well to improve performance of their end product.
Hence, they packaging their products prettily before they distribute to the market.

PRODUCTION MANAGEMENT
SFCC CHEMICALS AND CASTINGS SDN.BHD
The factory adopt batch production which make product based on customers demand. Refer to the
meaning of batch production that define as a form of manufacturing in which the job passes through
the functional departments in a lots or batches and each lot may have a different routing. So that
every product will be produce once customer placed the order. Then the next step they will proceed
until the end of the product and do the finishing. From that, the fact is shorter production is running
besides improve companys achievement.
So in a nutshell, the types of production is batch production and the demand per year is based on
customers demand.

BERYLS CHOCOLATE CONFECTIONARY SDN.BHD

They were adopting both types of production which is batch and mass production, they make order
based on customers demand and does the process in a line production which follow every section
that has been set up earlier. Based on concept of mass production, products produced by following
the flow of work smoothly.
So in a nutshell, the types of production is batch and mass production and the demand per year is
usually in high quantities.

QUESTIONS AND ANSWERS

SFCC CHEMICALS AND CASTINGS SDN.BHD

General Questions

Q : Are the sand used have a binder?

A : Yes, it have a binder to make sure the sand have the texture that we want and we want to
maintain the shape.
Q : How the workers separate the spru and the product when the material are fully set?
A : They separate the spru and actual product by using the hammer. with the force, they will
break.
Q : Metal that they used to make the product, are they can be recycle too?
A : Yes, we also melted the metal that we got from spru of the last product we made.

Production Management Questions

Q:Your factory used batch production to produce your product.Did your factory face any difficulty
by adopting these types of production?
A: Yes, we are. The production equipment uses a lot of space. When it's idle, this space is not being
utilized to make money.
Q:What is your company demand per year?
A:We dont have fixed demand per year.Our demand per year is based on customers demand.
Q:Based on what we have learned,disadvantages of batch production is required labor to move
items from one stage of the batch process to another,did your factory face this problem?
A:Yes,exactly.Labor is required for batch manufacturing.We usually lack of labor.

BERYLS CHOCOLATE CONFECTIONARY SDN.BHD

General Questions

Q : Where do this factory get the raw material with high quality from?
A : We got high quality raw material, cocoa from Ghana, where the quality were assured globally
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Q : What is your secret in attract customer to be regular and keep repeating order?
A : Our products for sure always maintain the quality and suits our customers taste. Plus, we also
practice Just In Time. We deliver the products on time in order to low the tardiness.
Q : You said that these product got higher demand from global market rather than local market, so
can you tell us the specific place that high demand come from?
A : Yes, the fact that global market demand more is true, especially from Japan, Korea and Indonesia.

Production Management Questions

Q:What is your company demand per year?

A:Based on our sales statistic but usually we produce our product in high quantities per year.
Q:Your factory used mass production to produce your product.Did your factory face any difficulty
by adopting these types of production?
A: Yes,the problem is when the equipment breaks down,the entire process is halted.Worse, if
equipment malfunctions,then all products become defected until the problem is found.
Q:By adopting mass production as your factory types of production,what benefits for you by using
this types of production?
A: The probability of human error and variation is reduced, as tasks are predominantly carried out by
machinery. Also a reduction in labour costs, as well as an increased rate of production, enables our
company to produce a larger quantity of one product at a lower cost than using traditional, nonlinear methods.

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CONCLUSION
We have been able to see in front of our eyes on how these companies manage their companies by
using batch and mass production. Next , with this observation , we increasingly understanding on
how these types of production carried out by a factory.We also have got deeper explanation about
how they process their product by adopting these types of production.Last but not least,we have got
useful on how the products going through the processes in order to produce high quality end
product.

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