Internship Report

SCHOOL OF ELECTRICAL & ELECTRONIC ENGINEERING UNIVERSITI SAINS MALAYSIA (ENGINEERNING CAMPUS)

INDUSTRIAL TRAINING REPORT 2013/2014

NAME MATRIX N0 COURSE IC NO TRAINING PERIOD TRAINING COMPANY

: ASNAWI BIN NOR AZIZAN : 112137 : ELECTRONIC ENGINEERING : 921024015845 : 23 JUNE 2014 – 7 SEPTEMBER 2014 : FUJITSU SDN BHD

FUJITSU COMPONENT (MALAYSIA) SDN. BHD.

ADDRESS

:

No.1, Lorong Satu, Kawasan Perindustrian Parit Raja, 86400 Parit Raja, Johor Darul Takzim, Malaysia.

ACKNOWLEDGEMENT

All praise and gratefully goes to Allah S.W.T. for His generous and loves eternally. First and foremost, I would like to dedicate my special thanks to General Affair & Training Section, FCM for giving me such a great opportunity to do industrial training in here. I’m feeling lucky and gratefully to have this once in a lifetime chance to be involved with this very well known company. The next person that I want to express my gratitude is Mr. Yiang Soo Keong, the assistant manager in Equipment Engineering Section who have open a big door for me to fully gain as much as experience and knowledge during 10 weeks training in this section. Not forget, Mr. Amat Sawal bin Surif, Mr. Soo Tech Ming, Mr. Khairul Anwar bin Zainal and Mr. Fauzi bin Khairun for being supportive and always have time to sharing all his experience and give good advice to guide me through this training period. Thank you for trained me technically and give me opportunity to do all the job part practically by myself. Last but not least, this appreciation goes to PM. Dr. Mohd Rizal Arshad, deputy Dean School of Electrical & Electronic Engineering USM, as he genuinely supervised me and give me full support to completing my training in here. In the mean time, I would like to dedicate my thanks to my parents, and a friend from UTM and Fujitsu also being so supportive and kindness to me.

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CONTENTS ACKNOWLEDGEMENT……………………………………………………………………………………………………….

1

LIST OF FIGURES……………………………………………………………………………………………………………….

3

LIST OF TABLES…………………………………………………………………………………………………………………

3

1.0 COMPANY BACKGROUD AND ORGANIZATION……………………………………………………………

4

1.1 COMPANY’S BACKGROUND…………………………………………………………………………………..

4

1.2 SUBSIDIARIES………………………………………………………………………………………………………..

5

1.3 FUJITSU COMPONENT (M) PROFILE……………………………………………………………………..

6

1.4 FUJITSU ORGANIZATION CHART…………………………………………………………………………..

7

1.5 PHILOSOPHY, VISION, AND MISSION……………………………………………………………………

9

1.6 QUALITY POLICY, ENVIRONMENT POLICY AND SAFETY POLICY…………………………….

10

1.7 6S CONCEPT AND BENEFIT…….……………………………………………………………………………..

11

1.8 ISO CERTIFICATION……………………………………………………………………………………………….

13

1.9 PRODUCT OF COMPANY……………………………………………………………………………………….

15

1.9.1 RELAY : BASIC OPERATION……………………………………………………………………………

17

1.9.2 COMPONENT OF RELAY………………………………………………………………………………..

18

1.9.3 RELAY MANUFACTURING BOARD…………………………………………………………………

19

1.9.4 CONSOLE OF RELAY……………………………………………………………………………………..

20

2.0 INTRODUCTION…………………………………………………………………………………………………………..

21

3.0 INTRODUCTION TO EQUIPMENT ENGINEERING SECTION…………………………………………..

23

3.1 EQUIPMENT ENGINEERING SECTION (EES)…………………………………………………………….

23

3.2 POSITION IN EQUIPMENT ENGINEERING SECTION…………………………………………………

23

3.3 PROCESS OF DESIGNING AND ASSEMBLING MACHINES…………………………………………

24

4.0 TASK DURING INDUSTRIAL TRAINING………………………………………………………………………….

25

4.1 TASK GIVEN……………………………………………………………………………………………………………

25

5.0 COMMENTS AND SUGGESTION……………………………………………………………………………………

33

6.0 CONCLUSION……………………………………………………………………………………………………………….

33

7.0 REFERENCES………………………………………………………………………………………………………………..

33

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LIST OF FIGURE Figure 1: Location Map of Fujitsu Component (Malaysia)…………………………………………………

8

Figure 2 : Scenery around Fujitsu……………………………………………………………………………………..

8

Figure 3 : Products of Fujitsu……………………………………………………………………………………………

16

Figure 4 : Relay Operation……………………………………………………………………………………………….

17

Figure 5 : Relay Components…………………………………………………………………………………………..

18

Figure 6 : Part of Relay…………………………………………………………………………………………………….

19

Figure 7 : Console of Relay……………………………………………………………………………………………….

20

Figure 8 : Company Cap and Scarf……………………………………………………………………………………

22

Figure 9 : Tools and Equipment in EES……………………………………………………………………………..

27

Figure 10 : Measure length of cable…………………………………………………………………………………

28

Figure 11 : Wiring complete …………………………………………………………………………………………….

28

Figure 12: Hole Drilling Drawing………………………………………………………………………………………

28

Figure 13 : Center Punch the hole mark……………………………………………………………………………

28

Figure 14 : Template Plotter Machine completely done…………………………………………………..

29

Figure 15 : Early Wiring Box…………………………………………………………………………………………….

29

Figure 16: Wiring Circuit Drawing…………………………………………………………………………………….

29

Figure 17 : Wiring Basic Circuit…………………………………………………………………………………………

29

Figure 18 : Wiring Box Complete……………………………………………………………………………………..

29

Figure 19 : Frame of machine assemble…………………………………………………………………………..

30

Figure 20 : Machine Parts………………………………………………………………………………………………..

30

Figure 21 : Soldering Wire………………………………………………………………………………………………..

31

Figure 22 : Wire assembly………………………………………………………………………………………………..

31

Figure 23 : Control Panel Switch Complete……………………………………………………………………….

31

Figure 24 : PLC Controller…………………………………………………………………………………………………

32

Figure 25 : Proximity Sensor…………………………………………………………………………………………….

32

Figure 26 : Ladder Diagram Coding………………………………………………………………………………….

32

LIST OF TABLE Table 1 : ISO CERTIFICATION…………………………………………………………………………………………….

13

Table 2: Schedule…………………………………………………………………………………………………………….

21

Table 3: Difference Uniform Colours……………………………………………………………………………….

22

Table 4 : Position on EES Department………………………………………………………………………………

23

Table 5 : Process on EES Department……………………………………………………………………………….

24

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1.0 COMPANY BACKGROUND AND ORGANIZATION STRUCTURE 1.1 COMPANY’S BACKGROUND Fujitsu Component (Malaysia) Sdn Bhd (FCM) is a Malaysian based subsidiary of Fujitsu Component Limited, Japan. Established in October 1980, FCM began commercial production of electromagnetic relay coils thereafter assembled by Fujitsu (Singapore) Pte. Ltd., then the parent company of FCM. Due to Fujitsu's globalisation policy and the recognition of FCM as a major overseas electromechanical devices manufacturing base, the ownership of FCM was transferred to Fujitsu Limited, Japan in June 1986. In July 1995, Fujitsu Takamisawa Component Limited was formed to strengthen the collaboration of technical expertise between Fujitsu Limited Japan and Takamisawa Electric Company Limited. FCM thus became a subsidiary of this newly formed company. Fujitsu Takamisawa Component Limited had since become Fujitsu Component Limited and Nagano Fujitsu Component Limited, with FCM being a subsidiary of Nagano Fujitsu Component Limited under Fujitsu Component Limited. Now FCM is a subsidiary of Fujitsu Component Limited, Japan. Today, FCM's product focuses on two key areas of electromechanical components – Relays and Keyboards, and their parts thereof. For support purposes FCM also manufacture dies and assembly machines for the electronic products. FCM products are sold through the worldwide network of Fujitsu Component sales offices, whilst technical and administrative supports are provided by Shinano Fujitsu Limited and Miyazaki Fujitsu Components Limited. FCM is an area of 78,000 square meters. In this area, FCM is able to produce a workforce of 1601 people, including contracts. In FCM, there are many section. For example, the production section, relay section, keyboard section, tooling section and Equipment Engineering Section. In industrial training, I was posted in equipment engineering section. Equipment engineering section (EES) is a section involving designing, programming and assembly new machines to use in production line.

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1.2 SUBSIDIARIES FMS – Fujitsu (Malaysia) Sdn Bhd Fujitsu (Malaysia) Sdn Bhd is part of the Fujitsu family of companies in Malaysia with Multimedia Super Corridor status providing customers in Malaysia with comprehensive state of the art information technology solutions. FCM – Fujitsu Component (Malaysia) Sdn Bhd Fujitsu Component (Malaysia) Sdn Bhd is a Malaysian based subsidiary of Fujitsu Takamisawa Component Limited, Japan, a company formed by Fujitsu Limited, Japan and Takamisawa Electric Company Limited, Japan. FTA – Fujitsu Telecommunication Asia Sdn Bhd Established in October 1995, Fujitsu Telecommunication Asia Sdn Bhd (FTA), a wholly owned subsidiary of Fujitsu Limited Japan, was initially set up as an engineering hub for engineering related activities to telco operators in Malaysia and progressed to be an Asian hub taking the role as technical support and information hub center in the region. FPCAP – Fujitsu PC Asia Pacific Pte Ltd Fujitsu PC Asia Pacific Pte Ltd (FPCAP) is the Asia Pacific Regional Headquarters for PC business of Fujitsu Limited, Japan. It’s responsibilities include the marketing and sales of a wide range of personal computers for the corporate and end-user markets in Asia Pacific.

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1.3 FUJITSU COMPONENT (M) PROFILE COMPANY NAME & ADDRESS

: FUJITSU COMPONENT (MALAYSIA) SDN. BHD.

No. 1, Lorong Satu, Kawasan Perindustrian Parit Raja, 86400 Parit Raja, Batu Pahat, Johor.

Contact Number

: 07-4542111

Facsimile

: 07-4541771

Industry

: Electric and Electronic component

Established

: 9th October 1980

Paid Capital

: RM 183 800 000.00

Capital allocation

: RM 200 000 000.00

Operation

: Since 1980

Ownership

: 100% owned by Fujitsu Component Limited

Fax Number

: 07-4541771

Date of Construction

: 9 October 1980

Operation Due

: June 1986

Product

: Keyboard and Relay

Status

: LMW- Licensed Manufacturing Warehouse

Man Power

: 1,482 work forces (June 2014)

Market

: Asia, US, and Europe

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1.4 FUJITSU ORGANIZATION CHART

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Location Map of Fujitsu Component (Malaysia)

Figure 1: Location Map of Fujitsu Component (Malaysia)

Figure 2 : Scenery around Fujitsu

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1.5 PHILOSOPHY, VISION AND MISSION PHILOSOPHY We will always strive to provide innovative, superior goods and services to our customers throughout the world. In doing so, we will establish and maintain harmonious relations both locally and internationally. We seek to make a positive contribution to world society.

VISION To be a global leader in Electro-Mechanical component parts manufacturing fully pleasing our customers.

MISSION Fujitsu specializes in the manufacturing and installation of specific products for the customers.

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1.6 QUALITY POLICY, ENVIRONMENT POLICY AND SAFETY POLICY QUALITY POLICY Over the years, FCM has built a reputation for providing top quality products and services to our worldwide customers. Our policy is “Quality Work Enhances Quality Product” In order to achieve the above objective, it is our policy to establish and maintain the efficiency and effectiveness of a quality assurance programme, and we continually plan and develop it in conjunction with all management functions in FCM: 

We look into the achievement of total quality management seriously.



We are committed to providing total quality in all activities by FCM.



We strive to provide quality products and services that exceeds our customer's requirements.



We believe that quality improvement is an infinite programme.



We will initiate Continuous Improvement in all production processes.

Quality is the hallmark of our success and will continue to be the mainstay of FCM's operations in future.

ENVIRONMENT POLICY We love nature.

SAFETY POLICY We ensure a safe and healthy work environment for all the employees and visitors.

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1.7 6S CONCEPT AND BENEFIT FCM is a flexible factory that can through ll the rise down market. 1. SEIRI (SORT) You must first ask what is actually you needed in an area. If you don’t use it, get rid of it and put what is left one-by-one. The things should we do: a) List down all the thins needed. b) Classify goods which are not use. c) Make a rule. 2. SEITON (ARRANGE) Everything has its own place and should be located where it is to be used and organized for a smooth flow. a) Placed all the equipment in arrangement. 3. SEISO (CLEAN) Remove dirty daily to keep good quality. When cleaning everyday, it’s becomes easy to see problems before quality defects occur. a) Clean up the entire machine and work area after doing job. 4. SEIKETSU (STANDART) Maintain what has been achieved. Mark areas where things belong and make sure they can stay tidy, orderly and clean. a) Make sure the uniform is suitable and safety. b) Ensure that all the equipment is labelled and in a right place. 5. SHITSUKE ( DISCIPLINE) Developing and maintaining new habits requires. a) Ensure that all the workers are follows the rule. b) Always wear appropriate clothes with name tag in working area. c) Smoke at the place provided. 6. SETSUYAKU (SAVE) Saving the cost of maintenance and production, such as electricity, water and etc. a) Ensure that all lamps and the water tap closed if not use. b) Walk and work fast. c) Use recycle paper.

d) Use an innovative way to save the work process.

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Benefit of 6S to Fujitsu: 

Productivity increase, reject decrease, output improve



Safety workplace, less industrial accident



Product quality gurantee, no customer refund



Cost decrease (Raw material, insurance, labor)



Reputation lead Customers trust



Delivery on time

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1.8 ISO CERTIFICATION The Fujitsu products are manufactured using highly automated processes and under the most stringent of quality control procedures. The information listed below shows the date of first certification for an ISO standard. Maintenance audits are conducted annually to ensure the continued adherence to the specification.

Facility/Factory

Certification

Date Certified

Fujitsu Component (Malaysia) Sdn Bhd ISO 9001:2008

June 22, 1993

Fujitsu Component (Malaysia) Sdn Bhd ISO 14001:2004

July 27, 1998

Fujitsu Component (Malaysia) Sdn Bhd ISO/TS 16949:2009 April 3, 2007 Table 1 : ISO CERTIFICATION

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SIRIM ISO 9001

SIRIM ISO 14001

SIRIM QS9000

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1.9 PRODUCT OF COMPANY

RELAY

Relay is one of electronic device which works as a switch to operate any electrical circuit

TOOL & DIE / STAMPING / MOUNT PART

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KEYBOARD

Figure 3 : Products of Fujitsu

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1.9.1 RELAY : BASIC OPERATION

Normal

Energized Relay (ON)

De-Energized Relay (OFF)

Figure 4 : Relay Operation 

Energized Relay (ON)

As shown in the circuit, the current flowing through the coils represented by pins 1 and 3 causes a magnetic field to be aroused. This magnetic field causes the closing of the pins 2 and 4. Thus the switch plays an important role in the relay working. As it is a part of the load circuit, it is used to control an electrical circuit that is connected to it. Thus, when the relay in energized the current flow will be through the pins 2 and 4. 

De – Energized Relay (OFF)

As soon as the current flow stops through pins 1 and 3, the switch opens and thus the open circuit prevents the current flow through pins 2 and 4. Thus the relay becomes de-energized and thus in off position.

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1.9.2 COMPONENT OF RELAY Base

Bobbin

Cover

Figure 5 : Relay Components

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1.9.3 RELAY MANUFACTURING BOARD

Coil Assembly

Base Mould

Semi Completed Relay

Cover

Completed Relay Assembly

Base Mould Assembly

Armature

Terminal

Spring

Coil Assembly Core

Figure 6 : Part of Relay

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1.9.4 CONSOLE OF RELAY

Figure 7 : Console of Relay

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2.0 INTRODUCTION The organization depends on the level of management of the company. It’s important to scheduling an activity in order to manage the work. Therefore, during the training here, I was given a regular work schedule. It has been provided to prevent me from having difficulty in linking a task during the training. For the information, this firm operated by morning and night shift. The shifts will change every 2 weeks. Morning Shift

Night Shift

7.00 a.m - 3.10 a.m

3.10 p.m -11.00 p.m

7.00 a.m - 7.00 p.m

7.00 p.m -7.00 a.m Table 2: Schedule

I was assigned to undergo training in according to office hours starting from 8.00am to 5.30pm. My supervisor also working at this hours, this will easier my job to asking something and avoid difficulty in learning. The allowance given is RM 10.00 per day. I was assigned to works for 5 days per week. Here I have provided some uniform dress that symbolize the Fujitsu citizens. It’s also shows the identity as a workers. When starting the job, I was given two pairs of regular uniform and a overall uniform to be used in the production section. The blue shoes also provided to used inside the buildings. Uniform application here is the same for all employees regardless of rank, but it’s distinguished by the use of colours which is scarves for women, hats for men.

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White

Conform Operator

Orange

Quality Control Operator

Pink

Inspection Operator

Green

Newly Trained Operator

Blue

Line Leader Senior Operator

Blue Black

Technical Staff / General Staff

Yellow

Material Handler

Cream

Human Resource Staff Table 3: Difference Uniform Colours

COMPANY CAP & SCARF

NEWLY TRAINED OPERATOR

CONFIRM OPERATOR

FCL Employee

LINE LEADER SR. OPTR

CUSTOMER

MATERIAL HANDLER

OPERATOR

QC OPERATOR

MATERIAL HANDLER

INSPECTION OPERATOR

QC OPERATOR

TECHNICAL STAFF

INSPECTION OPERATOR

STAFF

GENERAL STAFF

Figure 8 : Company Cap and Scarf

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3.0 INTRODUCTION TO EQUIPMENT ENGINEERING SECTION 3.1 EQUIPMENT ENGINEERING SECTION (EES) Equipment Engineering Section is one of department in designing and assembling the machines that will be used in the production line either in relay production or keyboard production. The designation of machines must have at least two persons in charge, from designing until it’s will be used in the production line. In this section, two persons will be in charge for one machine, which are electrical engineer and mechanical engineer. Both of them must works together to complete the machine. Sometimes, the engineer here is sending to the production line to do the production maintenance (PM) works. During my industrial training at Fujitsu Component (Malaysia), I was placed at Equipment Engineering Section to help the staff at Equipment Engineering Section to assemble, programing and wiring the machines from beginning to completion. Equipment Engineering Section is charged by Mr. Okabe Hitoshi who is the manager of Equipment Engineering Section and his assistant manager is Mr Yiang Soo Keong. Next, Mr. Amat Sawal bin Surif is my supervisor and his designation in Equipment Engineering Section is Senior Executive.

3.2 POSITION IN EQUIPMENT ENGINEERING SECTION: Name

Position

Okabe Hitoshi

Manager

Yiang Soo Keong

Assistant Manager

Amat Sawal bin Surif

Senior Executive

Soo Teck Ming

Executive

Md Fauzi bin Khairun M Khairul Anwar bin Zainal Table 4 : Position on EES Department

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3.3 PROCESS OF DESIGNING AND ASSEMBLING MACHINES NUMBER

PROCESS

1.

Design the machines using AutoDesk software.

2.

Program a ladder diagram coding using CXprogrammer software to use in PLC.

3.

Check the stock list that are ordered.

4.

Sort the stock in basket by parts.

5.

Assemble the machine by parts and wiring the machine.

6.

Alignment all part of machine.

7.

Assemble all the part.

8.

Machine is ready to operate.

9

Collect all the data of the machine. Table 5 : Process on EES Department

Table 5 shows the process in Equipment Engineering Section. These processes take time minimum, at least three to four month to complete. Then the staff’s in EES section must cooperate to each other in completing the projects to reduce the time taken to finished. For an example, one person do the electrical parts and programming, another do the mechanical parts and designing. By doing this, they will have no problem to cooperate each other.

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4.0 TASK DURING INDUSTRIAL TRAINING 4.1 TASK GIVEN For the first day my training in Fujitsu, I was assigned to look around the EES department to familiarize myself with equipment and tools that has provided. My supervisor also asked me to watch the other staff’s doing their works and asking if i don’t understand. By watching, I learned something and have ideas to do the work for the other next days. Mr. Yiang, who is the assistant manager of EES department said that, in EES Fujitsu, works as an engineer we must learn electrical, electronic and mechanical engineering. It’s because all of them are closely related to each other. In designing a machine, we must have the basic of this three. So, I have to learn the basic and skills on electrical, electronic and mechanical engineering. Here is some tools and equipment that I have discovered in EES department: Tools and Equipment Cutter  Mostly used for unpacking new stock from the box.

Image

Digital/Analog Vernier Calliper  It’s very accurate and used for measuring dimension. Mallet  Since it is soft and don’t leave any mark, suitable for knock the metal body

Hand Drill  Used to drill the hole

Drill Bit and Tapper  There are many sizes of drill bit and tapper. It’s depend on how we want to make the hole

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Oil Stone  Used to grind and hone the edges of steel tools and implements.

Alcohol  Used to cleaning the metal body from dust

Iron Solder  Joins two items together by forming a solid bond between the two objects with solder

Lead 

Material used for soldering

Adjustable/Fixed Spanner  Tighten the nut by adjust the spanner according to size of nut

Allen Key  Tighten the screw type allen head

Block Gauge  Mostly used for measure the dimension, in purpose of mark, because it’s very accurate

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Hot Dryer  Used for shrink the shrinkage tube

Magnet Block  Used in hold the block gauge from edge

Marker  Usually used in marking the wrong part of drawing

Scissor  Mostly used for unpacking new stock from the box.

Cable Tie  Used for holding items together, primarily electric cables or wires.

Wire Stripper  Used to strip the electrical insulation from electric wires

Google  Protect eyes from small pieces of metal

Figure 9 : Tools and Equipment in EES All of this tools and equipment are needed to designing and assembling the machines.

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Wiring 3 core cable for the machine ZN030-0123-U100, Coil Winding Unloader Stocker The first task I has given is to do some wiring 3 core cable for the machine ZN030-0123U100, Coil Winding Unloader Stocker. Mr. Sawal ask me to cut twelve 3 core cable length 200mm, which is needed for the machine. All measurement in Fujitsu are standardized to millimetre unit.

Figure 10 : Measure length of cable

Figure 11 : Wiring complete

In figure 10, shows how the 3 core cable is measured to strip the outer insulator. This method is taught by Mr. Sawal, since there are so many cable needed to striped, so we don’t have time to measure it by using an eraser. By using the thumb to measure the length, from my opinion it is good idea. This is the first skill that I learned from EES. After strip the cable, nylon connector male type is connected. Label is needed on each wire in order to easily the production maintenance (PM) do some maintenance if machine got problems. Figure 11 shows how the wiring is complete.

Drilling, Chamfering and completion the Template Plotter Machine Next, I had been assigned to drill and chamfer the Template Plotter machine. First of all, I needed to measure the point where the hole need to be drilled. Then, the point of the hole was marked by the center punch. After that, the mark was drilled by a driller by using the smaller drill bit first, before use larger drill bit. It’s to reduce the force when drilling the holes. For reducing the forces also, we can use grease oil. Chamfering was done after drilling to clear the burry of the hole. Lastly, the area of work was cleaned. Figure 12 shows the drawing to drilling hole and Figure 14 shows how the process is done.

Figure 12: Hole Drilling Drawing

Figure 13 : Center Punch the hole mark 28 | P a g e

Figure 14 : Template Plotter Machine completely done

Wiring The Wiring Box for P3 ADJ. CHECKER MAGAZINE LOADING UNIT Machine My partner which is from UTM student and I was assigned by Mr Soo Tech Ming to wiring the wiring box for machine P3 ADJ. CHECKER MAGAZINE LOADING. The process to assemble the component inside wiring box is quiet complicated. It’s because we need to think how the wire need to be assembled and located so it is not disturbed the other components.

Figure 15 : Early Wiring Box

Figure 16: Wiring Circuit Drawing

Figure 17 : Wiring Basic Circuit

Figure 18 : Wiring Box Complete

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Figure 15 shows the early wiring box which is not done anything. Figure 16 shows the wiring circuit drawing which is used as the reference to do the wiring later. Figure 17 shows wiring the basic circuit, which is must be done first before do the complicated wiring. This basic wire is a base of wiring. Figure 18 shows how the wiring box is completely done.

Assembling ZN030-0124-U100 project, FTR P3 Blowing and Covering Machine Md Fauzi bin Khairun was the person in charged in assembling these machines. This project had three units of machines to assemble. Unfortunately, I did not managed to help him to finish his project completely because my duration time of internship was not enough. As usual, the frame of the machine was set up. Then, my tasks given were to complete the assembling of the machine’s parts. Figure 19 shows that the frame of the machine was assembled.

Figure 19 : Frame of machine assemble

Figure 20 : Machine Parts From figure 20, shows the part of the machine ZN030-0124-U100 I has assembly, wiring

and alignment.

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Assemble, Wiring and Soldering Control Panel Switch Assembling, wiring and finishing the control panel switches for all the project that were assembled during industrial training at Fujitsu Component (Malaysia) SDN BHD. I managed to finish the control panel switch for ZN030-0123-U100 project, Coil Winding Unloader Stocker for two units and ZN030-0112-U100 project, Magazine Loading for one unit. When do the Control Panel Switch, the process done is soldering and assembling the wire. The wire must be solder with different type of colour and do the labelling. It’s to easily do the maintenance if the wire is damage. After the wire is solder, assembly process is done to ensure it is not to messy. The longer the wire is better than the shorter wire when want do the maintenance. The length of wire also must not exceed the covering box because it will be disturbed when do the maintenance by opening and closing the box.

Figure 21 : Soldering Wire

Figure 22 : Wire assembly

Figure 23 : Control Panel Switch Complete

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Learn Basic PLC Programming (Programmable Logic Controller) M Khairul Anwar bin Zainal is the programming engineer in Fujitsu. He was incharge in programming all the machines. I manage to learned the basic PLC programming and how the PLC is operate from him. Firstly, we need to know the input and output pins of PLC. Machine operation also is important if we want to do the programming, because we need to know how the machine is running. The coding that I learned is how to do the timer, counter and looping. Figure 24 shows the PLC use in Fujitsu. This PLC have six input pin, four output pin, one 24V pin and one 0V pin. There are limited of pin number on this PLC. So, we can’t do the complicated programming. If we want to do the complicated programming, we need more pins on PLC. Figure 25 shows the proximity sensor which use as input. Proximity sensor is high-frequency oscillation use to detect ferrous and non-ferrouse metal objects. In production, it is use to detect either the relay is arrive or not to do the next operation. Figure 26 shows how the ladder diagram is programed. This PLC use the logic concept such as, AND, OR, NOT and etc. In my opinion, it is easier to understand.

Figure 24 : PLC Controller

Figure 25 : Proximity Sensor

Figure 26 : Ladder Diagram Coding 32 | P a g e

5.0 COMMENTS AND SUGGESTION My industrial training that already last for 10 weeks has successfully opening my views of what this field is all about. But, what I have through during this period of time, I think that the time of my industrial training was not enough to get all the knowledge and to feel the true experience of working in industrial. Even though the period of training is very short, I’m satisfied because my training section has showed me the better working environments. I manage to do the multi skill on mechanical, electrical and electronic, thanks for that. My suggestion is, we need to grab all the knowledge and skills during the practical, because we have supervisor to supervise us. Since we are engineering students, industrial training is very important to expose us from the inside to the outside world in the field of engineering.

6.0 CONCLUSION Engineering study is incomplete without practical training. Theory is important as well as the practical experience to solve the challenging engineering problems. Undergoing training in Fujitsu Component (M) Sdn. Bhd. is good experienced to me. It’s a very good environment place to work. This is something fresh and this experience can’t be obtained in books or lecturers. Besides that’s, this training also help me to realize the real working environment that I will faced in the future, the communication skill between colleague and also self-belief about the professional role of an engineer in real situation. Before I ended this report, I would like to say: “THANKS FUJITSU COMPONENT (M) SDN. BHD. , THANKS EVERYBODY”

7.0 REFERENCES 1) http://www.fujitsu.com/my/about/subsidiaries/fcm/ 2) http://en.wikipedia.org/wiki/5S_(methodology) 3) https://www.ia.omron.com/products/category/sensors/proximity-sensors/

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