Professional Documents
Culture Documents
Full Report Haffis Mahmood
Full Report Haffis Mahmood
Full Report Haffis Mahmood
SEPTEMBER 2015
As time flies by for this past 12 weeks, I would like to show my gratitude to Allah as
for giving me the ease for all my activities being done during this particular period. Same
goes to my parents that has supported me in giving the advice and my necessary needs from
the very beginning until the end.
Thanks to Mr Annamalai that has been a very dedication supervisor to me. He shares
a lots of thing and useful knowledge to be the best employee. He also gives a lot of support
during my ease and hard time. Thanks also to Mr Izam Kamisian to be such a good supporter
and sporting visitor. His visit here has been so amazing and so cherish.
And lastly, to my fellow technition and mates throughout this industrial training, that
has been a joyful support members that loosen all my stress and problems. Thanks to all and
not to forget thanks to Yamaha thats allow me to do my industrial training here.
LIST OF CONTENTS
ii.
3 days class and Research and Development department (RnD Dept) ..................................... 19
5
CHAPTER 1 COMPANY BACKGROUND AND ORGANIZATION STRUCTURE
YEM is located in Chemor, Perak.Ia located about 15 kilometers from the city of
Ipoh. YEM produce audio visual products. YEM items are high quality and meet customer
needs, as it recognized the international world.
YEM construction cost of RM 31 million (USD 12.4 million), equivalent to the value
of the Malaysian currency of USD 1 = RM2.50 at that time. YEM factory was established not
far from the residential area to encourage people to come and work in YEM. YEM factory is
located in the industrial zone in Tasek where there are several other refineries in operation.
YEM operate the factory covers an area of 16 hectares (650, 000 square meters, 700,
000 square meters, 150, 000 square meters) .Size of warehouse is 240, 000 square meters,
258, 960 square feet, 121, 850 square feet. Football fields and parking lots each measuring
21,473 square meters and 5145 square meters.
The number of workers in YEM at the end of July 2015 was 1264 people, while the
average age of employees is 30 years. YEM workers of different ethnic groups such as
Malay, Chinese, Indian, Japanese and others. The percentage of workers is, Malay 61.96%,
China 10.3%, India 31.9%, Japan 0.82% and other races as much as 24.82%.
The following are the history line of YEM since April 1991 :-
As for the YEMs product, the following are the product produced by YEM :1. Receivers
Figure 3: RX-A3050
Figure 4: RX-V679
Figure 2: RX-V579
Figure 1: RX-V779
2. HiFi Components
Figure 6: CD-S2100
Figure 5: A-S2100
3. HiFi System
Figure 8: CD-C600
Figure 7: CD-S3000
Figure 9: MCR-042
10
ORGANIZATION STRUCTURE
11
12
CHAPTER II TRAINING GIVEN, DESIGNS AND PROJECTS
After running through this 12 valuable weeks in, I can say that Ive completed 6 mini
projects that is quite a lot of project within a short period in addition of completing the main
project chapter 3. Hence, as for the mini project, I have prepare the milestone chart to view
my management of this 6 mini project plus 1 main project.
Before that I must make it clear that the department that I was placed by the company
is one of the production line which is Surface Mount Technology (SMT). The following is
the flow of basic production line or in simple way is the product in the making flow/process.
AI
Auto insert
SMT
Surface Mount Tech
MI
FA
Manual insert
Final Assembly
13
AI
SMT Bonding
MI
MI
FA
SMT Bonding
3) SMT printing
SMT printing
MI
FA
4) SMT printing
SMT Bonding
MI
FA
FA
14
b.
ii.
iii.
iv.
v.
vi.
Kanban Project
vii.
15
I will continue briefly explain on the mini project for a clearer view about each mini
project is being done and whats its all about. This include, the main problem, the counter
measure and the results of the counter measure.
i.
The improvement of this project are :a. Reduce space since more box can be stack on top of the trolley because the
size has been increased
b. Easier to move the part boxes since the trolley got wheel to move it
c. Reduce/eliminate the presense of dust. This is really important because dust
can disturb when the machine want to mount theese parts.
d. Look tidier and cleaner which in Yamaha we follow the principe of 5S.
16
ii.
After a while in the storage section, I was assign to study part WW78390. This
part keep producing wrong polarity problem. We make a graph of the part
WW78390 to see the frequent part polarity problem occurred.
JUNE
JULY
VU99230
WY16320
ZP35860
WW78390
YF077A0
WY16460
ZF59760
WZ44340
VU99230
VV22070
Hence, we list some of the counter measure to overcome this wrong polarity
problem. The following are the counter measures:-
17
18
iii.
19
iv.
Later on for change model, I study the line leader report. I noticed that they
dont have a standard way of writing report. Hence, I follow their activity each
time their change model.
I see that there are actually, 4 basic activity during change model whicha are:a) Change model : include changing the program and setup backup pin jig
b) Parts arrangement : arrange nessessary part inside machine
c) Pickup teaching : technition teach the machine to perfectly pickup parts from
feeder.
d) Mount teaching : technition teach the machine to perfectly mount the part
pickup nicely to the PCW as desired
Hence, regarding this 4 matter, my supervisor organized a meeting and explain
to all the line leaders about this new standard of writing report. This is very
important because we need to analyse the downtime and the info inside the report
must be orgaized neatly.
v.
20
The following are the aim of understanding for this 3 days class.
understanding the manufacturing process
-
development stage
21
vi.
Kanban project.
Now the table is upgraded into a system. I was assigned to desing that
particular system using microsoft excel. This is a new experienced to me and my
opportunity to learn and build skills using microsoft excel. The following is my
desing for this kanban table.
This table are function to display a material request status. Line leader must
request parts form material 6hrs before change moder and ther also need to take
the requested parts 2 hrs before the change model. They can check the parts
preparation status inside the Kanban Table.
22
CHAPTER III MAIN PROJECT (PART FIX FOR MODEL MIX)
As for the main project, I feel lucky because my project was included as one of the
project in the YPM project. YPM that stands for Yamaha Productivity Management which
is an annual events for Yamaha thats open to all department to propose a project for their
particular department. As for the prize, the grand winner will get RM2000.00.
As mention before, SMTs has a total of 10 lines of production which are 5 lines are
for glue-ing parts on a PCB for a temporary time before the parts is soldered later on. And the
other 5 lines is for sweeping solder paste on PWB and directly heated to make the solder
strong and perfect for conducting electricity. Based on this, my supervisor and I decided to
choose line 5 to implement this YPM project.
Generally, the problems occurred that trigger to do this project for YPM is the time to
do a single change model is too long. This department goal is to make each single change
model for about 45 minutes. But practically the aim is hard to achieve. Hence we study back
and list the activity within the change model period and see which part can be improvise
(Kaizen). This is very important to this department because, we need to prepare the PCB to be
sent to our client which is the next line of production (MI : Manual Insert)
After studying the change model activity, basically the following are the activity
happen in each single change model :Change Model
Arrange Part
Pickup Teaching
Mounting Teaching
The single change model is considered done is when a PCB is completely has gone through
all the machine and mounted with no error.
23
Based on this 4 activities, the one that can be improvise is the ARRANGE PART.
Previously, arrange part take a lot of time because, they need to rearrange the feeder
for next model. The operator needs to checked the parts by referring to the set list and then
he/she will insert the feeder inside the machine. Later on, after all the feeder has been
inserted, then all the parts will be recheck and confirmed. Even by reading we can imagine
this takes a lot of time.
Hence, as for this project, I proposed to just choose a certain amount of model that
used similar parts mostly and the parts for these model will be fixed inside the machine.
Hence, no more arrange parts will be done and the operator will just confirmed the parts
before the machine runs. In addition, since less movement of feeder being take in and take
out, teaching time will also be reduced.
In short, the main idea is reducing the time by eliminate the arrange part activity and
fixed the necessary part inside the machine.
Firstly my supervisor and I set a target, which is to reduce the change model time
from 45 minutes to 30 minutes and this will be this project aim that need to be achieved.
Then we set a meeting to brainstorm the method and steps that need to be done in
achieving this. And the results we arrange it in a milestone table to be our guidance and to
keep on track of this project progress. The following is the milestone table :-
24
As for the effort point, we manage to start by choosing which model thats suitable
for this model. We choose the model that has quite similar parts used. Below are some
cropped part as an example how the model was choose and the list of the model chosen up
until now.
After this list of model has been prepared by time to time. Some of the program that
has been completed we already implement as planned in the milestone. But as for the
machine, how does the preparation for the machine?
25
About the machine, we study on the machine and find out that the machines slot is
not used optimally. Theres still some space that can insert part in it. As mention before, this
project is implemented in line 5. The following is the layout for the machine in line 5.
AI
SMT
MI
FA
Hence, we can see that we can add on up to 442 parts in total. Hence, we maximised
the usage of the slot and fixed the feeder inside the machine. Hence, there will be no more
arrange part since the part is already inside the machine, we only need to top up the parts if
the reel is empty. The following part we will discuss more on the results of this project.
26
RESULTS
Theoretically after the arrange part section being eliminated, the downtime for change
model will decrease and below is an example of this project results.
25
20
25
20
10
10
BEFORE
AFTER
MACHINE SETUP
PLACEMENT TEACHING
27
Individually, we can see that 30 minutes has been reduced due to the elimination of
parts arrangement. For the monthly analysis, we will total up all the change model time and
divide how many times does a single change model occur. This will give the average results
on the average change model time for that month.
As we can see above, even though we didnt achieve to make it up to 30 minutes per
change model, me manage to decrease the time lower that before. As this project has cut
down the time, around 10~20 min, this gives a very beneficial profit to the company.
Additional lot can be done and this will completely give profit to the company.
28
CHAPTER IV CONCLUSIONS
First of all, I would like to thank again to Allah, my parents, lecturer, supervisors and
friends for helping, guide,support and understand my needs for my industrial training from
the beginning until the end. When conducting this project, Ive learn quite a lot of new things,
interesting, instructive and challenging, knowledge and even good experiences during this
program. This program helped me to know more about what is the real meaning of
entrepreneurship, and I was able to gain new insights and more comprehensive understanding
about the real industry working condition and practice. After work there for 12 weeks, I
totally determined and eager to open my own business company in my future.
Based on my own opinion this company has the ability to grow up their business not
only to earn profit but also to make sure employees work in clean and hygienic place and
give important to the workers safety. On the other hand, the programme also has provided me
the opportunities to develop and improve my soft and functional skills.
In this programme I train myself the moral value of honesty, discipline, and
responsibility to take out the tasks assigned. This will surely increase the confidence in me to
do a given task with a sense of responsibilities. In addition, I also applied here in spirit of
teamwork and how to communicate with the workers here. Teamwork is essential to ensure
that a job can be completed within the stipulated time, while good communication among
employees is very important to create a working environment that peaceful and harmonize.
Indirectly, this can prevent boredom at work and can increase confidence in achieving the
perfect job.
The company has adopted the rule in many aspects. These regulations facilitate and
maintain the image of the role the firm to become more systematic. Finally, I would like to
conclude that this industrial training really gives me a working experiences that way beyond
that Ive imagine. But keep calm and face all kind of challenges or obstacles in order to be a
successful person in the future.
29
CHAPTER V PROBLEMS AND SUGGESTIONS ON TRAINING
After done my industrial training for 12 weeks , I can say that for an Electrical
Engineer to be, this is one of the best platform which this company produce the best
amplifier/ subwoofer. Hence, we will be learning the circuit or the production of the best
quality product in international level.
As for the sequence or which department should we be placed, I strongly suggest
request to stay in Research and development department but later on we can visit the
production line and see how they manufacture the design.
For me that has been been placed at one of the production line, theres a pros and cons
that Ive experienced. The good side is I got to see, touch, and do it myself how the pcb is
handled and managing a machine that mount component on the pwb. The other side is I dont
get to implement the knowledge that Ive been tought during my last 3 years studying in
UTM. But frankly, I make my own effort and request to make a 3 days class with the RND
engineers. These 3 days been so amazing since Ive get to design my own system and study
one of their best model.
In a nutshell, I once again strongly suggest that for the next internship batch to request
Yamaha Electronics as their industrial training place.
30
REFERENCES
i.
ii.
iii.
iv.
v.
31
APPENDIXES
DISPENSER MACHINE
ADHESIVE GLUE
WITH ADHESIVE GLUE
RESISTOR
CHIP MOUNTER
MACHINE
IC MOUNTER
CAPACIOR
DIODE
MACHINE
WITH IC COMPONENT
IC QFP
IC SOP
AOI MACHINE
1. SMT Glue
Dispensing Process
OUTPUT
32
PRINTER MACHINE
SOLDER PASTE
COPPER PAD WITH SOLDER PASTE
RESISTOR
CAPACITOR
TRANSISTOR
INDUCTOR
IC MOUNTER
MACHINE
DIODE
IC BGA
IC QFN
IC QFP
IC SOP
AOI MACHINE
WITH IC COMPONENT
OUTPUT