1.0 BACKGROUND OF COMPANY.

AMAT TEKNIK SDN. BHD was established back in February 1994. They are one of the

pioneer 100% Bumiputra Bolts & Nuts Manufacturer. In the mid year of 1995, they started

production with 2 units of machine.

It has proven since than to become one of the most efficient Bumiputra Fastener

Manufacturer. They cater wide range of local markets needs. Industries such as automotive, metal

base manufacturing, electronics and engineering works. Now with more than 20 units of machine,

they are capable of producing 150MT monthly.

In the beginning of their business, they concentrate in producing forging parts for automotive

and engineering, such as Hexagon Bolt, Weld Bolts and Nuts, Machine Screws and Tapping Screws,

Hexagon Head Screws, Carriage bolts and others. Their current major product is Nuts and Bolts

Weld with various size from M5 to 7/16UNF, Hook Hanger Mufflers from diameter 10mm to

12mm, Tube Towing Hook, Pin, Rivets, Rollers, Iso-fix, Sleeves, Holder Mounting and etc.

They plan to manufacture high grade and safety parts fasteners with mechanical properties and

conformity to National Standard like BC (UK ), JIS ( JAPAN ), ANSI ( USA ), SIRIM, DIN

( GERMANY ), and etc. In the future, Amat Teknik Sdn. Bhd., intend to produce and market bigger

range product due to domestic market demand and localization program. And at the same time to

improve the quality, service, cost effectiveness and technical innovation for both existing customers

and new customers.

With the current economic vast growth and great demand has promoted Amat Teknik Sdn.

Bhd. to invest on new advance technology in quality testing equipment. With the new technology,

their Automatic sorting machines which electronically detect ‘NG’ parts is capable to check and sort

600pcs/min. This actually streamlined with the Customers requirement towards ’ZERO DEFECT’.

With the wide range of quality product, Amat Teknik Sdn. Bhd. will widen the market needs and

simultaneously will fulfill our country ‘vision 2020’.

2.0 PRODUCT DESCRIPTION

Amat Teknik Sdn. Bhd. manufacturing a mass amount of nuts and bolts. They produced various

type of nuts and bolts with some metal stamping and machining products where it depending on the

customer needs. Here are the list of their products:-

2.1 Nut and Pin

Part Name : WELD

NUT

Part Size :M6 - M8

Colour : Plain

Part Name : ROUND

WELL NUT

Part Size : M8 - M10

Colour : Plain

Part Name :FLANGE

NUT

Part Size : 7/16 X

20MM Colour

: Black

Part Name : DOME

NUT

Part Size : M12 X

1.25P

Colour :PLAIN

Part Name : T WELD

NUT Part

Size : 7/16 UNF -

M16 Colour :

Plain

Part Name : CABLE

ADJUSTER

Colour : T/B

Part Name : PIN

RIVET

Finished :M7.8 - M10

Colour : T/B

Part Name : PIN

RIVET

Part Size : 01 – 02

Colour : Plain

Part Name :

PIN RR SEAT BACK

LOCK Colour :T/B

Part Name : PIN

SELECT

Part Size : 8mm X

57mm

Colour : T/B

2.2 Bolts

2.3 Metal Stamping and Machining Product

2.4 Other Products

Part Name : SPACER STRUT HOUSE

Part Size : Ø25mm x 12mm x 25mm

Part No : PW592054

Part Name : NUT PUSH ON SPRING

Part Size : Ø3mm - Ø4mm

Part No : PW823856

Part Name : BUSH A, BUSH B

Part Size :Ø10mm - Ø12mm

Part Name : ROLLER

Part Size : Ø10.95

Note : Roller Seat

3.0 MANUFACTURING TECHNOLOGIES, PROCESS AND SYSTEMS

At Amat Teknik Sdn Bhd, they have various machines which run at the same time to produce many kind of nuts, bolts and

some other products. These are the machines which owned by Amat Teknik Sdn. Bhd. :

BIL MACHINE ORIGIN

PRODUCT

SIZE

(MM)

PRODUCT

LENGTH

(MM)

OUTPUT

(PCS/MIN)

OUTPUT

DAY

(PCS/DAY)

CATEGORY

1.

FORMER

Bolt Former JBF10B

Taiwan M4-M8 8-55 250 90000 AUTO

2.

Bolt Former JBF17B

Taiwan M8-M16 16-75 240 86400 AUTO

3.

Nut Former NF14B

Taiwan M4-M8 11 240 86400 AUTO

BIL MACHINE ORIGIN PRODUCT PRODUCT OUTPUT OUTPUT CATEGORY

SIZE

(MM)

LENGTH

(MM)(PCS/MIN)

DAY

(PCS/DAY)

4.

HEADER

NF14B

Taiwan 8-12 MAX 150 160 57600 AUTO

5.

ZH25

Taiwan 8-10 8-55 75 27000 AUTO

6.

ZH20

Taiwan 6-12 15-50 60 21600 AUTO

7.

YH15

Taiwan M3-M6 5-55 120 43200 AUTO

BIL MACHINE ORIGIN PRODUCT

SIZE

PRODUCT

LENGTH

OUTPUT

(PCS/MIN)OUTPUT

DAY CATEGORY

(MM) (MM) (PCS/DAY)

8.

THREAD

ROLLING

JBF 10B

Taiwan M4-M8 8-55 250 90000 AUTO

9.

JBF 10B

Taiwan M4-M8 8-55 250 90000 AUTO

10. Taiwan M4-M8 8-55 250 90000 AUTO

11. Taiwan M4-M8 8-55 250 90000 AUTO

BIL MACHINE ORIGIN PRODUCT

SIZE

PRODUCT

LENGTH

OUTPUT

(PCS/MIN)

OUTPUT

DAY

CATEGORY

(MM) (MM) (PCS/DAY)

12.CIRCULAR

SEWING

MACHINE

Cutting 1

Taiwan 0.5 -100 - 2 720 AUTO

13.

Cutting 2

Taiwan 0.5 -100 - 2 720 AUTO

14. WELDING

IM-300 MIG

Malaysia - - 1 1 MANUAL

The Mechanism of Bolt Former

1. The air clutch brake system has been designed to allow the motor to start from no load

condition, and also able to actuate as "Inching", "Single Stroke"  and "Continuous Running". The

main side will always stop at rear position when operating either "Single Stroke", or "Continuous

Running" cycle.

2. The solid cut off die and knife ensures a square cut and clean edges.

3. The cut off cam follower is designed at the center of the cut-off carrier rod to avoid eccentric

force occurred on the cam follower pin and to maintain the rigidity and longevity of the machine.

4. The positive knock-out cam in the punch side was designed by computer to achieve simplicity

and precision Punch side knock out timing coincides with the main slide movement to prevent

spill out of materials from forming die before knock out.

5. The last station rear knock out mechanism can do normal slow motion knock out by simply

changing the knock out cam which is designed for easy replacement.

6. The main machine parts like frame or main slide has been normalized to release the internal

stress after casting. It means to avoid deformation in the future and keep precision forever.

7. All cam diagram in this machine is designed by Computer program and machined through

Machining Center (MC) to gain smooth surface and accuracy.

8. The stability and precision of the main slide is secured by "Overran" designed and the

application of harden alloy steel plates fixed to it will help maintain its precision for a long

period of operation.

9. This machine is equipped with automatic checking device, called Auto-Checker, which will

sensitively stop the machine and to indicate to your operator in case of:  

» Mal-function of front punch knock out

» Mal-function of rear ejection

» Overload

» Materials short feed

» Production reach to counter pre set figure

A limit switch mounted in front of the straightened wheels will automatically stop the machine

when the material runs out.

The cut-off mechanism and its drive have been simplified. The cut-off roller is supported on both

ends for rigidity. The picture also shows the balancing weight on transmission gears.

OTHER FEATURES

1.

The semi finished products are pushed out of the dies by three knock-out levers which are independently adjustable. They are controlled by a camshaft underneath. The third cam can be easily changes for trimmed or untrimmed bolts.

2.

The main slide extends to the rear of the crankshaft for better balance. The yellow colored lever is the synchronized positive knock-out lever for the front punches. Since the motion is synchronized with the connecting rod, it is independent from the position of the main slide.

3.

The picture shows that maximum working areas is provided. The longitudinal position and the alignment adjustment for the forming die and the three front punch are independently adjustable. The mounting and dismounting of the punch is affected by one screw.

4.

Gripper transfer shaft is running freely and smoothly on Liner Bush. The Gripper mechanism can be swung up for die change and the cassette type gripper slide base can be taken off the machine for quick set up

PRODUCTION FLOW CHART

FORGING

ZH 25

ZH 40

YH 15 NF 148

BF 178

BF 208

SECONDARY

PROCESSTHREAD STAMPING

CUTTINGTAPPING DRILLING

LATHE

CHECKING

S-110MTY-60MT Y-80MT

TR 25TR 20

4.0 QUALITY AND SAFETY SYSTEM

Upon our visits to Amat Teknik Sdn. Bhd., we enormously agreed that this company have certain

standard regarding their quality and safety system. They are particular about this matter and look

forward to have a better standard in this area of production in the future.

4.1 Quality Policy and Quality Objective

100% MANUAL CHECKING

BOLT SORTING M/C

NUT SORTING M/C

Quality policy

We are committed to achieve our quality policy which is:

“To produce quality products and continuance improvement for customer’s

satisfactions”

Quality objective

We are committed to achieve our three quality objective which are as

follow:

To achieve 100% delivery to our customers

To ensure customer’s complaint not more than 1 per year

To maintain production rejection rate not more than 1% per year

4.2 Quality Control Equipment

AUTOMATIC OPTICAL SORTING MACHINE

AUTOMATIC OPTICAL SORTING MACHINE

Quality objective

We are committed to achieve our three quality objective which are as

follow:

To achieve 100% delivery to our customers

To ensure customer’s complaint not more than 1 per year

To maintain production rejection rate not more than 1% per year

3D CAMERA MEASURING SYSTEMTENSILE TESTING

DIGIMATIC HIGH GAUGE HARDNESS TESTER

5.0 SUMMARY

The assumption is generally made that more care in maintenance would cure the

problem, or at least prevent it being a danger. Many consider, including bolt and nut,

that the fundamental cause of the problem is design, rather than maintenance, related.

Poor maintenance practices obviously have played a part in many failures, but

manufacturers insisting upon frequent torque re-checks is an indictition that the joint

design on many wheel assemblies is marginal. The inherent variation in bolt and nut

preload as a result of torque tightening can result in the forces acting on some wheel

assemblies exceeding the bolt and nut capabilities to resist them.

6.0 APPENDIX