Industry Visit Report

UNIVERSITI TEKNOLOGI MARA

MEM560 MANUFACTURING PROCESSES

PROGRAM CODE

:

EM220

GROUP

:

EMD5M1A

LECTURER

:

ENCIK ABDUL GHALIB

DUE DATE

:

19th DECEMBER 2014

NO 1 2 3 4 5

STUDENT’S NAME

ID NUMBER

MUHAMMAD HAZIM FAHMI BIN MOHD YAMIN

2012226818

MOHAMAD ZAID BIN MOHAMAD ZAILANI

2012241394

MUHAMAD SHAFIQ BIN SAUFI

2012876726

AHMAD HASSAN BIN MUHAMMAD MUHAYYIDIN

2013411786

MUHAMMAD SYAHIR BIN AHMAD ZABIDI

2013440952

Ma n u f a c t u r i n g P r o c e s s e s (MEM560)

INDUSTRY VISIT REPORT

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Ma n u f a c t u r i n g P r o c e s s e s (MEM560)

Contents 1.0

DISTRIBUTION OF WORK AMONG MEMBERS .................................................................................. 4

2.0

Introduction ...................................................................................................................................... 5

2.1

COMPANY PROFILES ..................................................................................................................... 5

3.0

OBJECTIVES OF THE VISIT .................................................................................................................. 6

4.0

FINDINGS ........................................................................................................................................... 7

4.1

MANUFACTURING PROCESS ......................................................................................................... 7

4.1.1

INCOMING ............................................................................................................................. 8

4.1.2

STAMPING ............................................................................................................................. 9

4.1.3

WELDING ............................................................................................................................. 11

4.1.4

ASSEMBLY ........................................................................................................................... 12

4.1.5

QUALITY CONTROL .............................................................................................................. 14

4.1.6

OUTGOING .......................................................................................................................... 15

8.0

REFERENCES .................................................................................................................................... 18

9.0

APPENDICES .................................................................................................................................... 19

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Ma n u f a c t u r i n g P r o c e s s e s (MEM560)

1.0

DISTRIBUTION OF WORK AMONG MEMBERS MOHAMAD ZAID BIN MOHAMAD ZAILANI

• objectives • stamping • SOP

MUHAMMAD HAZIM FAHMI BIN MOHD YAMIN

• Manufacturing Process • apendices

MUHAMAD SHAFIQ BIN SAUFI

• intro • Assembly

AHMAD HASSAN BIN MUHAMMAD MUHAYYIDIN

• outgoing • references

MUHAMMAD SYAHIR BIN AHMAD ZABIDI

• Incoming • Quality Control

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Ma n u f a c t u r i n g P r o c e s s e s (MEM560)

2.0

Introduction 2.1

COMPANY PROFILES

Established over two decades ago, in the year 1988, Autokeen Sdn. Bhd. is a private limited company specializing in metal parts manufacturing and assembly specifically for the automotive industry, among a host of other products and services offered. With a paid-up capital of RM5 million, and strategically located in the industrial hub of Shah Alam, Malaysia, Autokeen has carved a niche for itself and is recognized as Malaysia’s prominent manufacturer of automotive metal parts.

Figure 1 : Autokeen building

It prides itself for its strategic partnerships with automotive industry giants Proton and Perodua, for the manufacture and development or new car models. Twenty five years of strategic planning, steady growth, and complete customer satisfaction have ensured that Autokeen has emerged as a leader in the industry. The company continues to diversify and grow through previous and existing customers, who have benefitted immensely from the high quality products and services provided by the company, as well as new customers who eagerly trust Autokeen with their requirements. The finest workforce coupled with the latest technology in a state-of-the-art manufacturing facility enables Autokeen to provide its customers with products and services that consistently exceed their expectations. Autokeen design, develop, engineer and manufacture high quality metal stampings and assembly for the automotive industry.

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Ma n u f a c t u r i n g P r o c e s s e s (MEM560)

3.0

OBJECTIVES OF THE VISIT

The objectives of the visit are:

1) To understand the processes involved in details about producing a high precision product.

2) To observed the working environment in the industries regarding mechanical. 3) To fulfill the requirement needed in the manufacturing course subject in the Mechanical Engineering Faculty

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4.0

FINDINGS 4.1

MANUFACTURING PROCESS

There are so many product that were manufactured by Autokeen where mostly parts of a car. Beside that, they also manufacture a dies but only for small size since there are limitation of their facility . There are some die used in this company which it can perform several process. During in this visit we had choose one product to see how it being manufactured. So we had choose an Proton Alza parts named REINF S/A DASH PANEL C/MBR. To produce this part of Proton Alza, it will go through several processes such stamping, welding ,assembly and quality work inspection also being perform for all subs part before delivery.

Incoming Stamping Welding Assembly Quality control Outgoing Figure 2 - Manufacturing step

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Ma n u f a c t u r i n g P r o c e s s e s (MEM560)

4.1.1

INCOMING

There are two types of incoming into the production line which are material or secondtier. The secondtier incoming is where the vendor sent the half-ready product for the factory to weld and assemble to get the finished product. The secondtier incoming is directly sent to production lines which are welding and assembly. As for the incoming material, it can be divided into two forms which are coil and strip. The examples of incoming materials in the factory are mild steel, SPC, NTHD, SPD, SPDE and SGACE. The incoming material must undergo stamping process before proceed to the production line. After stamping process, there are some products do not need to undergo welding process but just proceed to assembly process. But there also some products that only undergo welding process after stamping process and proceed to PDI. Other than that, there are also products that need to undergo all the processes before it can be transport. Usually, the suppliers supply the incoming materials 2 weeks earlier for the factory to produce the products. The factory usually ordered more number of incoming materials or supply. For example the D87A product, the number of products need for December are 10500 unit, the factory will ordered 11000 unit in case of defects that may be happen during the production.

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4.1.2

STAMPING

There are three types of stamping machine available in Autokeen factory which can be categorize by the size of the product small, medium and large. Dies price between RM100,000 to RM200,000. One part of product usually will go through several stamping process where each stamping are different process such a bending, pearcing and blanking process. The manufacturing process of REINF S/A DASH PANEL C/MBR begin with Raw plate material where will through stamping process. Stamping process started with part drawings or CAD data design provided by customers for small to medium press machines. Small die were made by using CNC milling. Design given by the customer are develop by Autokeen Design Engineer to fabricate dies, assembly jigs, hand gauge, checking fixtures in support of the above parts development. REINF S/A DASH PANEL C/MBR consist of two part where one of it need to be stamped by large press machine. The large press machines are very huge and it can do the stamping processes with high pressure. The press machines are 1200 – 800 – 800 - 600 tan per stamping. Those machines are CNC machining and can produce a lot number of products in a time. The average time per one stamping process is 5 to 10 seconds. The large products are obtained from these large press machines. Another part of this product need to be stamped by medium press machines . The medium press machines are producing medium-size products. It is also can do the stamping processes with relatively high pressure. The tan per stamping for medium machines is 800 – 500 – 500 – 500 which the process per stamping is forming – trimming – piercing – shaping respectively. Most of the products from the Autokeen are undergo medium press process. The medium machines are also CNC machining.

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Ma n u f a c t u r i n g P r o c e s s e s (MEM560)

Figure 3 : Stamping machine

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Ma n u f a c t u r i n g P r o c e s s e s (MEM560)

4.1.3

WELDING

Welding is at the heart of metal fabrication . Autokeen provide welding and assembly services of modular parts and components utilized by their clients, manufacturing sub assembly of body panel metal stamping parts using various types of spot welding machines such as robotic spot welding, stationary spot welders, portable, projection MIG welders. Since this part consisting of three subs part, welding assembly need to be done to join them together. The welding of the products can be divided into two which are Welding Stationary Spot (WSS) and Welding Assembly Portable (WAP). The WAP is the welding at the spot which bolt and nut are later to be attached. The types of welding that are used in the factory are Gas Metal Arc Welding (GMAW), spot welding and spark welding. The spot welding is done by using guns which can be divided into two which are S-gun or C-gun.

Figure 4 - S-gun and C-gun

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Ma n u f a c t u r i n g P r o c e s s e s (MEM560)

Figure 5 - welding point

4.1.4

ASSEMBLY

By using a jig, the products is being assembled. There are a lot of jigs needed in order to produce one part. During this process, there are workers that checking the features of the products. The standard tolerance is

when there are some products exceeded the

tolerance given, the products can be rework. Defect, usually occur during cutting process caused by blunt cutting tool creating burr on cutting edge. This burr will creating a gap between two parts of the product and spot weld could not be proceed, hence the burr need to be removed. The burr removal can be done by using grinder.

Figure 6 - Burr

Figure 7 - Gap

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Ma n u f a c t u r i n g P r o c e s s e s (MEM560)

Figure 8 - Final Product

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Ma n u f a c t u r i n g P r o c e s s e s (MEM560)

4.1.5

QUALITY CONTROL

These are some aspect that are being evaluated, where workers need to ensure all of the aspect were performed.

In this quality control specific on welding points, in this section worker needed to ensure 7 spot welding were done at all red point below, 4 nut(M6) placed at yellow point, 2 bolt(M8) placed at grey points, flange nut(M8) at blue point and lastly 4 stud weld manually done at four green points.

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4.1.6

OUTGOING

Finally, the complete assembly product then will be ready for delivery to their customer, to be exact this product will be sent to PRODUA company to complete the assembly of Produa Alza. Below are some of product which being manufactured by Autokeen for PRODUA.

Figure 9 - other product

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Ma n u f a c t u r i n g P r o c e s s e s (MEM560)

The standard operation procedure (S.O.P) for the assembly process is:

STEP 1

STEP 2

STEP 3

STEP 4

STEP 5

STEP 6

STEP 7

STEP 8

STEP 9

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Ma n u f a c t u r i n g P r o c e s s e s (MEM560)

STEP 10

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Ma n u f a c t u r i n g P r o c e s s e s (MEM560)

8.0

REFERENCES 1. http://www.thelibraryofmanufacturing.com/ 2. http://en.wikipedia.org/wiki/List_of_manufacturing_processes 3. http://en.wikipedia.org/wiki/Outline_of_manufacturing 4. http://www.autokeen.com.my/about-us/

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9.0

APPENDICES

Figure 10 - Taking Photo with Autokeen manager

Figure 11 - Autokeen Building

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