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KULLIYYAH OF ENGINEERING

INTERNATIONAL ISLAMIC UNIVERSITY MALAYSIA

ENGINEERING INDUSTRIAL TRAINING


AT
SONY EMCS (MALAYSIA) SDN.BHD

FAIZ NAIM B RAHAMADDULLA


0835897
MATERIAL ENGINEERING
2012
DEPARTMENT OF MATERIAL & MANUFACTURING ENGINEERING

KULLIYAH OF ENGINEERING
INTERNATIONAL ISLAMIC UNIVERSITI MALAYSIA

18 JUN 2012 5 SEPT 2012

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

Industrial Internship program

1.1.1

Scope Of Training

1.1.2

Internship Objectives

1.1.3

Internship Goals

1.1.4

Scope Of Works, Tasks ,Projects and Gaant Chart

1.2

Host Company Background

1.2.1

Sony

1.2.2

The Vision behind the name

1.2.3

The Guiding Vision

1.2.4

The Mission

1.2.5

The Essence of Sony

1.2.6

History Of Sony

1.2.7
1.3

5 S Concept In Sony Emcs (M) Sdn. Bhd.


Department Background

9
11

SUMMARY OF ACTIVITIES OF INDUSTRIAL


TRAINING

14

PROCESS FLOW

16

3.1

Introduction

16

3.1.2

AD-7930 Series (Hybrid Line)

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

Operator Entering the Line

32

4.5.5

Adjustment

33

4.5.6

Production

33

4.5.7

Improvement

33

4.5.8

Steps To Take Tact Time

34

SELF-ACTIVITIES

40

5.1

Slide Guide Shaft Project

40

5.2

Stopper Platen On Rail Project

43

5.2.1

Introduction

43

5.2.2

Photosensor

44

5.2.3

Relay

44

DISCUSSION

45

RECOMMENDATION

47

7.1

Recommendation For Host ( Sony Emcs (M) Sdn.Bhd)

47

7.1.1

Provide PIC to train internship student

47

7.2

Suggestion And Recommendation For IIUM

48

7.2.1

Reconsider Daily Report

48

7.2.2

Weekly Logbook

32

CONCLUSION

49

APPENDICES

51

LIST OF FIGURES

FIGURES

TITTLES

PAGE

1.2.1

Sony EMCS Sdn Bhd

1.2.6

Sony EMCS Plant Map in Malaysia

3.1

Original Process Flow

19

3.2

New Proposal For Process Flow

21

4.1

Schedule For Setup Line ESS-04

23

4.3.1

Line Layout ESS-02

25

4.3.2

Line Layout ESS-04

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

INDUSTRIAL INTERNSHIP PROGRAMME

Industrial Internship program is meant for a programmed that is dedicated


for learning by doing after the theory and knowledge has been taught. Specifically,
industrial internship program is dedicated to give the university student to undergo
the training in the related industry, out of the class formality to build the student
potential in job market.
Undergo the industrial training is an important aspects for the student. This
training is one of the compulsory courses that have been listed in the curriculum of
International Islamic University Malaysia (IIUM).

1
1.1.1

SCOPE OF TRAINING

The scopes of this training are:

I.

To position the student into related industry/organization to give an


exposure, experience as well as professional skills in all aspects of
Engineering .

II.

To have a skilled, responsible and high morality of engineer ethics.


III.

To open the opportunities for the industry to have a permanent


employee.

1.1.2

INTERNSHIP OBJECTIVES

The purpose of Industrial Internship Programmed is to introduce the students to the


real working environment. From this program, the students will experience
responsibilities as an engineer and also exposed to the ethic in engineering. Besides,
this program will develop skills in communication and management. The detail
objectives of the program can be listed as below:

To integrate theories and practices. Student would be able to utilize and


implement their knowledge and skills in a real working environment. This
internship program will give student a chance to see an overall view of
working in Industry.

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.

To give opportunity to students to work with industrial practitioners.


They can gain so much knowledge and experiences from the expertise. This
can raise eagerness for students to work in electronics business companies

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.

To expose students to potential employers. Students have an advantage


and opportunities to work for their Host Companys during their internship
period after they graduate later.

1.1.3

INTERNSHIP GOALS

i)

Placing students in industry / relevant organizations to provide


exposure to experiences and professional skills to the students in
various aspects of engineering and computer science.

ii)

To produce an efficient, responsible and behave engineers.

iii)

Opportunities for industrial training trainees absorbed as permanent


employees in industrial training.

3
1.1.4

SCOPE OF WORKS, TASKS AND PROJECTS

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.

To learn the process flow of each line.

To learn the procedure to setup new line including wiring process,


setup table as well as dressing wire.
III.

To involve in SMI activities that covered line balancing and


innovation to improve works performance.

IV.

To involve in self-activities which is projects such as Slide Guide


Shaft and Stopper Platen On Rail Project.

4
1.2 HOST COMPANY BACKGROUND

1.2.1

Origin Sony EMCS (M) Sdn. Bhd

Figure 1.2.1 : Sony Electronics (M) Sdn. Bhd

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 VISION BEHIND THE NAME

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 Guiding Vision

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.

Sony's mission is to establish an 'ideal' factory that puts emphasis on


the spirit of freedom and open-mindedness. A place where designers and
engineers can work out their creative and technological skills to the highest
potential

1.2.4

The Essence of SONY.

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.

Innovative ideas are the most important aspect of creating Sony


products. Technology supports those ideas afterwards, but the ideas must come
first. To create products that alter the industry, we must have the ability to
foresee future trends and the unlimited imagination to dream up new products.

Most important of all, we must not only think of today, instead we


must think three to five years from now. We must be very perceptive to what
our customers want. We want our customers to say, "I am glad I purchased a
Sony product," so we must create products that pull at their heartstrings.
7

1.2.6

History of SONY EMCS


SONY EMCS Corporation is either one families of SONY. SONY

EMCS corporation established on 15th JANUARY 1987 at Malaysia and open


ceremony by Y.B. Tan Sri Dr. Mahathir.
SONY EMCS (Malaysia) Sdn. Bhd. EMCS means as follow:
E = Engineering

M = Manufacturing
CS = Customer Service

Figure 1.2.6
Sony EMCS Plants Map in Malaysia

8
1.2.7

Sony Company 5S

1.2.7.1 Phase 1 Seiri


Sorting: Going through all the tools, material, etc., in the plant and work area
and keeping only essential items. Everything else is stored or discarded.

1.2.7.2 Phase 2 Seiton

Straighten or Set in Order: Focuses on efficiency. When translate this to


Straighten or Set in Order, it sounds like more sorting or sweeping, but the
intent is to arrange the tools, equipment and parts in a manner that promotes
work flow. For example, tools and equipment should be kept where they will
be used (i.e. straighten the flow path), and the process should be set in an or
der that maximizes efficiency. For everything, there should be place and
everything should be in this place. (Demarcation and labeling of place.)
1.2.7.3 Phase 3 Seiso
Sweeping or Shining or Cleanliness: Systematic Cleaning or the need to keep
the workplace clean as well as neat. At the end of each shift, the work area is
cleaned up and everything is restored to its place. This makes it easy to know
what goes where and have confidence that everything is where it should be.
The key point is that maintaining cleanliness should be part of the daily work
not and occasional activity initiated when things get too messy.

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.

1.2.7.6 Phase 6 Safety


A sixth phase, Safety, is sometimes added. Purist, however , argue that
adding it is unnecessary since following 5S correctly will result in a safe work
environment. Often, however a poorly conceived and designed 5S process
can result in increases in workplace hazard when employees attempt to
maintain cleanliness at the expense of ensuring that safety standards are
adequately followed. There will have to be continuous education about
maintaining standards.

When there are changes that will affect the 5S

program such as new equipment, new products or new work rules it is


essential to make changes in the standards and provide training. Companies
embracing 5Ss often use posters and signs as a way of educating employees
and maintaining standards.
10
1.3.

DEPARTMENT ORGANIZATION CHART

CHAPTER 2

SUMMARY OF ACTIVITIES OF INDUSTRIAL TRAINING


I spent my internship at SONY EMCS (Malaysia) SDN. BHD. BANGI
NORTH PLANT as an electrical and electronic engineering trainee. The internship
program was started on 18th of JUN 2012 until 5th of SEPT 20112 I was assigned into
ITC division under Manufacturing Engineering (ME) department. The purpose of
this department was to setup new line and to create an innovation and improvement
through SMI.

During 3 months (12 weeks) of my internship program at ME department, I


was involved in many tasks and activities. I have been trained to understand process
flow, setup new line, create innovation, line balancing, undergo projects and many
more. From this, I have learned to be more creative, innovative and critical minded
since my job is not only focus on electronic engineering only but also involve in
other course such as mechanical engineering.

The internship program thought me a great deal. Technically, I had the


opportunity to apply what I have learned during my study especially on Autotronic
Engineering Lab and PLC (Programmable Logic Circuit) since I had been given a
few projects such as Slide Guide Shaft and Stopper Platen On Rail Projects. I also
learnt a lot of new thing about wiring the relay and sensor besides what I already
learned in IIUM. At the same time, I was exposed to project management,
administration and teamwork. I also experienced office culture and improved my
social and communicational skills.

Despite some challenges, the internship was a great success. I grew as an


electrical and mechanical engineer in all respects and it very much prepared me for
life after graduation.

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

AD-7930H SERIES (HYBRID LINE)

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.

As an example, the operator at SUB-04 and the station involved for


recombined is GA-01, we cannot combine the process if the station is not related to
each other. So before combining the process we must know that the processes done
by operator are related or not to each other station. Apart from that, we also have to
brainstorming whether it is possible to combine or split the process. In order to
combine or split the process, I have to discuss with my teamwork. That is why it is
important to study the process first if we are not very familiar with processes done
by a line.
17

Observation

Refer line
balancing

Brainstorming

Discussion

Finish

After combining the processes, we wrote the proposal of recombined process


flow. Finally, the new proposal of this process flow will be deliver to my supervisor
for further action. After I send the proposal to my supervisor, there will be a meeting
with the person in charge (PIC) from production engineer. During the meeting, my
supervisor will present the proposal. After discussion, the production engineer will
finalize the process flow. Finally we can draw the draft of line layout after
confirming the draft of process flow is accepted .

18

Figure 3.1 : Original Process Flow


19

20

Figure 3.2 : New Proposal For Process Flow

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

Figure 4.1: Schedule for setup line 970 ESS-04

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-

Figure 4.3.1: Line Layout ESS-02

25

Figure 4.3.2 : Line Layout ESS-04


26
ESS-04 line is a hybrid line which improved after setting ESS-01 until ESS03 lines. Based on Figure 4.3.1, the total manpower for a line is 71 persons is
decreased to 37 persons for new hybrid line. The total space required also decreased
as we can conclude that this new hybrid line has its own advantage compared to the
current line.

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)

After that, we planned the quantity of table needed in a line. We cannot


easily examine the quantity of table is same with quantity of manpower. It is because
there are different shapes and sizes of table depend on the process flow done by a
station. The types of table can be refer to Figure 4.4.1, Figure 4.4.2, Figure 4.4.3,
Figure 4.4.4, Figure 4.4.5, Figure 4.4.6 and Figure 4.4.7.

4.4.1

Type of tables:-

Figure 4.4.1 : Table 50


28

Figure 4.4.2 : Table 90

Figure 4.4.3 : Flatness table

29

Figure 4.4.4 : Railing table

Figure 4.4.5: Packing table

30

Figure 4.4.6 : Packing box

Figure 4.4.7 : Packing box


31
4.5.1 MATERIAL SETUP

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.

4.5.2 EQUIPMENT SETUP

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

4.5.3 BUYOFF PROCESS

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

The improvement is done when weekly SOEM Manufacturing Innovation (SMI).


The tact time for each station will be taken to know which station have problem. The
data of tact time will be recorded and converted into line balancing.

4.5.8 STEPS TO TAKE TACT TIME

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.

That is why we need to understand the process flow because we


already knew the process for each station. We also must alert the quantity of

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.

Figure 4.5.8 : Line Balancing

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

Figure 4.5.8.2 : Cause And Effect Diagram

The improvement done during SMI is not only focused on bottleneck


station. The quantity Work In Progress (WIP) also will be focused on. It is because
the objective of doing improvement in a line is to reduce the quantity of WIP. I was
given a task to study about why there are too many WIP. There are four stations
around this WIP and I must make sure that this WIP is belongs to which station.
After identifying the station, I must observe the problem facing by operator in that
station. Then think an idea to solve the problem.
For example:-

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.

Figure 4.5.8.3 : Movement Waste

38

Figure 4.5.4 : Checklist missing items

39

CHAPTER 5

SELF-ACTIVITIES

5.1

SLIDE GUIDE SHAFT PROJECT

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
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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.
.

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5.2

STOPPER PLATEN ON RAIL PROJECT

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

A photosensor is an electronic component that detects the presence of visible


light, infrared transmission (IR), and/or ultraviolet (UV) energy. Most photosensors
consist of semiconductor having a property called photoconductivity , in which the
electrical conductance varies depending on the intensity of radiation striking the
material. The most common types of photosensor are the photodiode, the bipolar
phototransistor, and the photoFET (photosensitive field-effect transistor). These
devices are essentially the same as the ordinary diode , bipolar transistor , andfieldeffect transistor , except that the packages have transparent windows that allow
radiant energy to reach the junctions between the semiconductor materials inside.
Bipolar and field-effect phototransistors provide amplification in addition to their
sensing capabilities.
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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.
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CHAPTER 6
DISCUSSION

As been briefed before, one of the basic criteria to be completed by a


International Islamic University Malaysia student is to undergo a practical training
or better known as industrial internship program for the period of twelve weeks.

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.

As the objective of IIUM to produce an all rounded students, this internship


programme serve as a platform for them to gain as much skills needed such as
communication and behavioural skills, lifetime learning capacity, posses technical
competence, practical aptitude and solution synthesis ability.

Working and studying are completely different in term of definition. But it is


undeniable that we will continue the learning process even though we are working.
Either working or studying, the person has to be determined and self-centred to
success in whatever realm they are in.

From observations and experiences gained during practical training, the


author have learnt the way every workers tackle any rising problem and how they
manage to complete the task within the time interval. As been discussed earlier, it
really helps IIUM in order to fulfil its objectives towards producing the all rounded
graduates.

CHAPTER 7

RECOMMENDATION

7.1

RECOMMENDATION FOR HOST (SONY EMCS (M) SDN. BHD.)

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

7.1.2 Provide PIC (person in charge) to train internship student

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.

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7.2

SUGGESTION AND RECOMMENDATION FOR IIUM

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

Reconsider Daily Report

Based on experience, daily report can be redundant and supervisors may be


too busy to mark them. Trainee doesnt learn new things every day and sometimes
we were required to do the same work every week. So, writing about the same
activity every day can be redundant. It is better if the report is made based on
activities / project or on monthly basis.

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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.

The Industrial Internship Program is a good and successful program. The


author also feels really proud to undergo industrial internship training at Sony and to
be a member ME Department. The author really appreciates the time that has been
spent during the training at Sony EMCS (M) Sdn. Bhd.

The underlying objectives should be achieved together in parallel with total


cooperation between all personnel involved, either from host-company or IIUM. It is
suggested that improvement should be done to remedy all weaknesses and trainee
should be given a chance to learn, adapt and familiarize themselves with working
experience.

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CHAPTER 9

APPENDICES
Stopper Platen On Rail Project

Power Supply

Relay
51

Solenoid Valve

Plunger
52

Plunger advance when touch the sensor

Plunger retract when release the sensor


53