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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
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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.
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
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
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.
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
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.
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.
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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
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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.
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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.
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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.
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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.
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���� 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)
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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
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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.
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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.
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PRODUCTION MANAGER
LEAD, MANUFACTURING
LEAD, ENGINEERING
ENGINEERING GROUP
LEAD, ELECRICAL
MANUFACTURING GROUP
ELECTRICAL GROUP
ASSISTANCE MANAGER
CHART 2: ORGANIZATIONAL STRUCTURE OF THE PRODUCTION DEPARTMENT
Industrial In-Plant Training Report at Active Precision Sdn Bhd
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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
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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)
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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,
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� 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.
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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.
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� 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
Industrial In-Plant Training Report at Active Precision Sdn Bhd
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� 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
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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
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� 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
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� 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
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� 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
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� 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
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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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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)
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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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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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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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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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� 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
Industrial In-Plant Training Report at Active Precision Sdn Bhd
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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
Industrial In-Plant Training Report at Active Precision Sdn Bhd
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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
Industrial In-Plant Training Report at Active Precision Sdn Bhd
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� 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
Industrial In-Plant Training Report at Active Precision Sdn Bhd
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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
Industrial In-Plant Training Report at Active Precision Sdn Bhd
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� 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
Industrial In-Plant Training Report at Active Precision Sdn Bhd
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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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� 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
Industrial In-Plant Training Report at Active Precision Sdn Bhd
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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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� 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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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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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.