Sasi Mid Report

8/13/2019 Sasi Mid Report

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CHAPTER 1

INTRODUCTION

COMPANY BACKGROUND

The history of Clipsal

Founded in Australia in 1920, Clipsal has become one of the leaders in electrical

accessory products, known for its innovation and quality, in Asia

1920! Alfred "erard developed the product that #ave the company its name, an

ad$ustable, one si%e &clips all' metal conduit fittin#

(he company spearheaded several manufacturin# breakthrou#hs, includin# the first

all)Australian switch in 19*0 +n the 190s the company pioneered thermoplastics

which led to world firsts includin# the -.C Cord top, vertical combination switched

socket and more

/urin# the 190s the company be#an eportin# to Asia well before it became the

practice of Australian companies (he famous 3eries accessories proved to be very

popular throu#hout the Asian re#ion +n the 40s and 90s the Clipsal brand continued

to epand on the stren#th of many innovative products, reachin# its market leadin#

position that it currently en$oys

+n the last decade, the company5s /atacomms division has for#ed ahead as a market

leader in the data communications market while the company5s C)6us automation

technolo#y has become the main supplier of buildin# and home automation to both

commercial and residential markets

7ver the years, Clipsal has #rown and evolved with #reat success (heir marketin#

initiatives and consumer campai#ns ensure commitment to valued customers 3ome

of the more prominent initiatives include ) Club Clipsal +nternational, /emand (he

6rand, Clipspec and (he ssential Checklist

I !""#$ %&hei'er Ele&tri& a&()ire' Clipsal* (his important acquisition fulfilled a

vital niche for the 3chneider lectric "roup, securin# market leadership of the

Australian and Asia -acific electrical accessories residential market and a ma$or

stron#hold in the automation and data communication markets*

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The history of %&hei'er Ele&tri&

%&hei'er Ele&tri&+s Ti,elie

From 14*8 to today, 3chneider lectric has transformed itself into the #lobal

specialist in ener#y mana#ement 3tartin# from its roots in the iron and steelindustry, heavy machinery, and ship buildin#, it moved into electricity and

automation mana#ement After 10 years of history, 3chneider lectric has become

today the solution provider that will help you make the most of your ener#y

/iscover its transformation below

19th century

1-#.! (he 3chneider brothers took over the Creusot foundries (wo years later, they

created 3chneider Cie

1-/1! :avin# become an armaments specialist, 3chneider innovated by launchin#

itself into the emer#in# electricity market

First half of the 20th century

1/1/! +nstallation of 3chneider in "ermany and astern urope via the uropean

+ndustrial and Financial ;nion estin#house, a ma$or

international electrical #roup (he "roup enlar#ed its activity to manufacturin#

electrical motors, electrical equipment for power stations and electric locomotives

Post 0ar! 3chneider #radually abandoned armaments and turned to construction,

iron and steel works and electricity (he company was completely reor#anised in

order to diversify and open up to new markets

?ate 20th century

1/-11//2! 3chneider "roup continued to focus on the electrical industry by

separatin# from its non)strate#ic activities (his policy was #iven concrete form

throu#h strate#ic acquisitions by 3chneider "roup! (elemecanique in 1944, 3quare /

in 1991 and @erlin "erin in 1992

1///! /evelopment of +nstallation, 3ystems and Control with the acquisition of

?eel, urope5s number two in electrical distribution +n @ay 1999 the "roup was

renamed 3chneider lectric, to more clearly emphasise its epertise in the electrical

field (he "roup en#a#ed in a strate#y of accelerated #rowth and competitiveness

arly 21st century

!"""!""/! -eriod of or#anic #rowth, positionin# itself in new market se#ments!

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!"1"! 3chneider lectric stren#thens its lead in the development of the 3mart "rid,

with the acquisition of the distribution activities of Areva (/

!"11! 3chneider lectric acquires leadin# software firm (elvent to reinforce its

solution capability for the smart #rid and mission)critical infrastructure

Malaysia Operatios ,ilestoes

Fi#ure 11! (ime ?ine

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Pro')&t Ma)fa&t)re'

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ORGANI3ATIONA4 CHART

1*!*1 Or5ai6atioal Chart of Clipsal 7y %&hei'er Ele&tri& 8M9 %'* Bh'*

Fi#ure 12! 7r#ani%ation Chart

7

@y self attach to -roduct

n#ineerin#

3A3+(:ABBA

REDDY


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%&hei'ere build stron# &o,petiti>e a'>ata5esthrou#h our industrial operations

and #lobal supply chain mana#ement

>e raise our i')strial a' s)pply &hai &o,pete&ies to the best

worldwide level

>e develop a culture of &oti)o)s i,pro>e,etwith the contribution of

every employee, every day

>e make all of our decisions based on s)staia7le 'e>elop,et

?e see a 0orl' 0here 0e &a a&hie>e ,ore$ 0hile )si5 less of o)r

&o,,o plaet*

>e know that ener#y demand will skyrocket whilst we will have to

drastically cut ":" e also know that more

than 0G of ":" emissions, are caused by industry buildin#s and residential

markets (herefore, we provide ener#y efficiency solutions that can brin# up

to *0G of ener#y savin#s, now

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1*@ OBECTI;E% AND UNCTION% O DEPARTMENT ATTACHED

Pro')&t E5ieeri5 Tea,

+n my case, + was in product n#ineerin# team, the ob$ectives of this department are !

-rocess of desi#nin# and developin# a device, assembly, or system such that

it be produced as an item for sale throu#h some production manufacturin#

process

-roduct en#ineerin# usually entails activity dealin# with issues of cost,

producibility, quality, performance, reliability, serviceability and user

features

(hese product characteristics are #enerally all sou#ht in the attempt to make

the resultin# product attractive to its intended market and a successful

contributor to the business of the or#ani%ation that intends to offer the

product to that market

+t includes desi#n, development and transitionin# to manufacturin# of the

product (he term encompasses developin# the concept of the product and the

desi#n and development of its mechanical, electronics and software

components

-roduct en#ineerin# is an en#ineerin# discipline that deals with both desi#n

and manufacturin# aspects of a product

Area of Resposi7ility

-roduct en#ineers define the yield roadmap and drive the fulfillment durin#

ramp)up and volume production,

+dentify and reali%e measures for yield improvement, test optimi%ation and

product costturability methods,

/efine qualification plan and perform electrical characteri%ation analysis

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!*1*# Tools Use' Har'0are a' %oft0are %pe&ifi&atios

System Application and Product in Data Processing (SAP)

3A- is the JsoftwareJ enterprises Besources -lannin#


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+mprove the monitorin# and control functions

Beduce the common errors made by humans ity

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i5)re %ho0s the Proe&t tea, Me,7ers

The pro7le,s a' %ol)tio

i5)re %ho0s the Before a' after the ;E

As you can see in the fi#ure this pro$ect that we did which is Beduce si%e of

contact point from mm diameter to mm diameter 6y doin# this action wemana#e to save and capture the savin# for our company, from initial 1029

@KB to 0929 @KB

i5)re %ho0s the Before a' after the ;E

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As you can see in the fi#ure this pro$ect that we did which is -/C31*2@

chan#e type AB(: (B@+A? A33K)D 6y doin# this action we mana#e to

save and capture the savin# for our company, from initial cost for per piece

19 @KB to 04809 @KB

(he savin# that we mana#e to capture are about 00k uro per annual last year due

to H. cost reduction /etail as below

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Fi#ure! 3hows the (op 10 H. pro$ect and the Cost Beduction

!*1* D)ratioF%&he')le*

(he schedules are classified and confidential, are not to be circulated out the

company :owever, + am safe to say that the duration for this pro$ect is really

depends on the approval by the B/ team from Australia and China

!*! PROECT ! TRIA4 RUN ON THE PRODUCT%

J(rial BunJ is a process that must be undertaken by the -roduct n#ineerin#


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completion of this trial run After that all, we can proceed to release the LB@-5

release for mass production

!*!*! Te&hi()eFMetho'olo5y Use'

1 Choose a product


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After knowing the product, download the list of components using

SA transaction code !"S12#.

2 -lanner plan to carry out a trial run

After #ettin# the date, time and place of conductin# a trial run, HA

and (rainers ?eaders Assembly will be invited to $ointly conduct a

trial run

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* "et results on Jtrial runJ

After conductin# a trial run, the product will be tested by HA whether

the product is eperiencin# the problem or not

+f you do not eperience any problems, the products can be carried out

in production

+f the product is eperiencin# the problem, the - should solve the

problem.

Tools Use' Har'0are a' %oft0are %pe&ifi&atios

System Application and Product in Data Processing (SAP)

3A- is the JsoftwareJ enterprises Besources -lannin#


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* +mprove the quality


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Check the pin le# etensions usin# multimetres

EECTOR PIN CONDITION

+f the pin surface is not flat or too short to not be in contact with continuity

on the product, replaces the pin with a new pin

Dete&t PRODUCT %EN%OR F PU%H BUTTON

J-/3J is a device used to move the product in the JrailJ bo to run the

eperiment without usin# hand pressure forces

(ester uses detector sensor products

-ush 6utton Jfunction similar to theJ -/3 Jbut does not use the sensor tester

(ester is usin# its pressure to move the product

+f J-ush 6uttonJ eperiencin# problems due to re#ular use, replace J-ush

6uttonJ to new

4CD %CREEN

A display for displayin# each of the problems eperienced durin# the process

of product trials performed

%CRE? CONDITION

Checkin# the screws from the product

+f there are no screws on the product, JFaulty li#ht Mwill flash

%AETY CO;ER

Checkin# the JcoverJ to JcoverJ is in #ood condition

RAI4

Check whether there is a problem in the part or not

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4ATCH

Check whether there is a problem in the part or not

Relays

Check JrelaysJ functions or not

3creenin# is done by usin# a multimeter

AIR CY4INDER T)7i5

Check the inner cylindrical tube either loose or wind out there

%O4ENOID ;A4;E

amine the JsolenoidJ if there is any problem

MCB

+s the power supply

Check with the multimeter in #ood condition or not

4IMIT %?ITCH

Connect the pin

+f there is a problem of a missin# screw J, checkJ limit switch Jas likely to cut

wires

solderin# method is a solution to the problem

TRAN%OMER

Checkin# the functionality of the variables

+f there are any problems, replace with J(ransformersJ new

HIGH ;O4TAGE 4IGHT

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(he tool checked by HA

+f the li#ht is on, all trial on the products is in #ood condition

CY4INDER

/efinition! )

-neumatic Cylinders

;sin# air pressure differences to produce a style and movement Chan#e the

air potential ener#y, mechanical ener#y applied to the kinetic ener#y of

motion stren#th (he pneumatic system can drive I interestin# I lift somethin#

ob$ects or #oods

%O4ENOID

/efinition! )

(he term physics)wire loop >hen an electric current flow, the ma#netic field

will be produced A variety of transducer devices that convert ener#y into

linear

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Figures of Tester

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$igure% Tester $ront &iew

$igure% Side &iew

$igure% Top &iew

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!*!*@ Pro7le,s a' %ol)tios Of The Pro7le,s

1. roduct%'ESM15

Huantity! )4

3uccessful! )

ot successful! )*

-roblem! ) -roduct burnt after the trial M:i#h).olta#eM


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(. roduct%'1661L-XX-YY

ro)lem%'*ot ha+ing a shutter in the product.

"ause%'error of the operator.

Results% perators imposed disciplinar- action form.

/=-roduct!)The so&=et

-roblem!)All components installed in the product enou#h, but durin# the trial the

MtesterM failed

pectations!)(erminal ? I I cannot be in effect in the MtesterM

Cause!)(he problem of the MtesterM

Res)lts 819!):alf a successful product after the MtesterM in repair and clean

3u##estions! +nstall MdoubleM tab in the MtesterM near the end of the trial process in

the current product tester for the product stable and steady

Res)lts 8!9!)3uccessful, but these methods are only temporary

!*!* D)ratioF %&he')le

(he schedules are classified and confidential, are not to be circulated out the

company :owever, + am safe to say that the duration to complete this task take few

weeks due to people viability for the test run for me to conduct and the to analy%e the

defect of the problems

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!*# PROECT # CANDO AND BI44 O MATERIA4 8BOM9

!*#*1 Tas= Des&riptio

Ca'ois a typical process plant to provide products that are rarely produced that is

not listed in the catalo# with a small chan#e at a time 3uch conditions must be met

before the pro$ect Cando Amon# them are! )

1 -roducts can be reali%ed without modification of new tools or production

equipment

2 (he product does not have any ma$or chan#es and ma$or additions and chan#es in

the function of the product to avoid risk of quality and production accountin#

* Beceivin# a purchase order parts and special packa#in#

BOM is a list that contains the item number and quantity of each component in each

measurement components 67@ also contains a bill of materials complete and

formally structured list of installation components or products

!*#*! Te&hi()eFMetho'olo5y Use'

(he methodolo#y used are same as previous pro$ect < -ro$ect 222 = 6ut the

setup of 67@ will be /ifferent from the previous pro$ect (he 67@ usa#e of this

pro$ect will be as!)

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Fi#ure! 3hows the 67@ setup process

Fi#ure! 3hows the 67@ structure for this pro$ect

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Fi#ure! 3hows the 67@ Chan#e on @ass production

!*#*# Tools Use' Har'0are a' %oft0are %pe&ifi&atios

(he hardware and the software used are similar with the previous pro$ect


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Fi#ure! 3hows the variable -arts

Fi#ure! shows the .ariant 6om setup

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Amon# the important aspects before creatin# the J.ariant 67@J is! )

i Cannot create a J.ariant 67@J as J@ultiple 67@J

iiCannot create a J.ariant 67@J of a component or product already has the bomb

itself

iii (he basic unit of measurement of all the different materials must be the same as

the basic unit of measure in the material master record

Fi#ure! 3hows the eample of .ariant 67@

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Fi#ure! 3hows the .ariant 67@ in the -lant

!*#* D)ratioF %&he')le

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CHAPTER # TRAINING$ ?ORK%HOP %EMINAR

#*1 Traii5$ ?or=shop %e,iar

#*1*1 )ality ;al)e E5ieeri58;E9 0or=shop

H. is the process where we reduce the cost without affectin# the quality of part or

product .alue en#ineerin#


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#*1*! CMI JP4U%+ Co,poet Mo)l'i5 Istr)&tio Pl)s Traii5

(his trainin# is about to have better moulded parts in order produce effective

production in the factory +n this trainin# briefly we #et to know how to prepare or

mould the parts in order to #et less defect and to increase our mouldin#

efficiency(his trainin# is conducted by the mouldin# epert @r7liver

@aus


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CHAPTER @

%UMMARY

@*1 PROECT TA%K IN;O4;ED %UMMARY

(he pro$ects which + involved are all stated above 7verall those pro$ects done are

very useful for me to be considered as my future references >hen + am in the

-roduct n#ineerin# team + learnt about the role of a -roduct n#ineer /espite that +

have learned how to have #ood communication skills, improved my troubleshootin#

skills and also learnt about the drawin# on how to read the technical aspect of it

Finally + were here to basically know everythin# about a product n#ineer works

:owever, the tasks + have been doin# in 3chneider are not only pro$ects related $obs,

but also thin#s related to -roduct /urin# my time with the -roduct team, + helped to

involve myself in the H. pro$ect where the pro$ect which involves of cost

reduction process ven thou#h + spent only few days with the team, + mana#ed to

learn about the H. system and the method used

Furthermore, + will also assist whoever in my department needs my help + was called

to assist with another team leader to help them do some test Althou#h help them,

they all are very kind)hearted because they never been headache and hesitate to teach

me

Apart from assistin# my collea#ues, + will also do my own testin# on the products +

was first #iven base to test with, learnin# its function and its protection practically by

checkin# its /imension and fittin# test, to#ether with the functionality test

/espite all those hands on tasks, + will be concentratin# on readin# the products

manuals on my free time for the handbooks + am to produce before my internship

ends As a conclusion, the trainin#s, pro$ects involvement and task #iven by

3chneider are truly useful + believe that it has #iven me much knowled#e in such a

short time

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@*! %UGGE%TION OR IMPRO;EMENT

+t is recommended that the company can or#ani%e trainin# for all the product

personnel re#ardin# the internal parts of the switch for eample how the internal of a

circuit breaker actually operates as all these should be the basic knowled#e for a

testin# personnel and they should know well on what they are dealin# with instead of

$ust repeatin# the same routine in testin# without understandin# it (he company can

also conduct courses or trainin# on the equipment used for testin# as the testin#

personnel should be very clear on what equipment they are dealin# with and its

ha%ard

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$igure .1% $A/R Report

$igure .2% Drawing appro+ed for production

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$igure .(% $itting test inspection

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$igure .% "ompliance test report

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$igure .0%Test Report

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$igure .% Test hoto

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$igure .% Trou)leshoot on the 3ase

$igure .4% 35 creation using SA software

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$igure .6% 5oulding department on the top +iew

$igure .17% Assem)l- Su) cell

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$igure .11% 5ap to "lipsal )- Schneider Electric 5ala-sia

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Sasi Mid Report