ACKNOWLEDGEMENT It is compulsory for a M. I. T student to pass the industrial training before being awarded the TRAIN&PLACE. Student will be attached to industrial, firm or companies for a specified period of time, to be exposed to the actual working environment whereby student will encounter many new problem and challengers. The primary purpose of this guideline is to provide guidance to students to prepare themselves to face these new challengers and face the real life working. It also to ensure that they abide by the rules and regulations of M. I. T and the training organizations.
It is hoped that M. I. T student will undergo the industrial training successfully, effectively and to the best of their ability while maintaining the good name and reputation of M. I. T. Objective of M. I. T ACADEMY industrial training programmed • To expose student to actual working environment. • To enhances the student’s knowledge and skill. • To instill the qualities of integrity, responsibility and self-confident. • To expose student to safety practice and regulation in industry. • Ti instills the spirit of teamwork and good relationship between students and fellow workers. To assess the student’s ability and competency in their preparation to join the work force upon completion of their studies in M. I. T.. • To get more knowledge about industries village. • Teach students how to work in organization and how process will run in production. ABSTARCT During my training at Flexible Machining System Sdn Bhd, I have been sending to VMC (Vertical Machine Center) department. It is was a manufacturing department, which all product that have been receive from sawing department or any other department for every machining process before it going to other department for next process.
In this department, I have working for being a setter and operator to operate the VMC machine. Which is mean I have to setting the machine in time that have been give to me. Beside that, I have to help my supervisor in setting the machine to make sure the process is follow the procedure. I also have been teach by my supervisor in how to do the work by using the work instruction and Work flow. These are example of my works that I have to do which are: ? Work Instruction ? Machine Maintenance ? Machine Setter ? Jigs setter. ? Manufacture the jigs. ? Production Setter. History Head office and Factory of Flexible Machining System Sdn Bhd.
The Flexible Machining System (FMS) Group is made up of 3 companies operating in the Rawang. There is a Tractor Line Industries, Man Hydraulics System and Acestahl Organization. Tractor-Line was incorporated in 1989 with only a small factory, has since evolved as a leading manufacturer in tractor and hydraulic replacement parts as well as OEM for automotive parts and components. At the forefront of the industry, our involvement is not limited to the manufacturing level but the entire integrated process from designing to production, machining to engineering, repairing to maintenance, raw materials to finished goods, and packaging to delivery.
Technologically equipped with state-of-the-art and fully-computerized machinery, our team of European-trained engineers and technicians certainly have the defined edge in meeting even the most stringent and specific requirements. And with our bi-weekly evaluation, our customers can rest assured that they are furnished with the latest market information, technological know-how and global techniques from time to time. Flexible Machining System is a group in the worldwide provides one-stop metal-work solution for wide range of industries that insist on world class quality.
The corporate vision is to be the best at what we do. To be a global player in the metal working industry by providing Total Customer Satisfaction, Superior Value, Quality Leadership and Innovation Technology. Flexible Machining System group aims to make this happen through the consolidation of resources of the companies under it wings:- 1) Tractor Line Sdn Bhd (TL) 2) Man-Hydraulic System Sdn Bhd (MAN) 3) ACESTAHL HLODINGS Mission To provide one-stop metal-work solutions for a wide range of industries that insists on world-class quality.
Flexible Machining System Group aims to make this happen through the consolidation of resources of the companies under its wings Tractor Line Sdn Bhd, Man-Hydraulic System Sdn Bhd, and Acestahl Sdn Bhd Vision One Stop Centre with Assurance of Quality. To be a global player in the metal working industry by providing Total Customer Satisfaction, Superior Value, Quality Leadership and Technology Innovation. FLEXIBLE MACHINING SYSTEM SDN. BHD [pic] Flexible Machining System SDN. BHD. Flexible Machining System SDN. BHD Established in 1989, Flexible Machining System Sdn Bhd was initiated as a vendor to the national car project.
Over the years it has grown from strength to strength and has seen encouraging expansion of its products and services. Currently Flexible Machining System Sdn Bhd lists several of the major automotive part and component manufactures as its clients. Among the services presently being carried out at its plant in Rawang, Selangor. Man-Hydraulic System Sdn Bhd is a member of Flexible Machining System Group, primarily responsible for the Malaysia’s largest manufacturer in replacement parts for tractors, heavy equipment, and hydraulic cylinders for mobile and industrial sectors as well as automotive OEM parts.
Quality leadership. FLEXIBLE MACHNING SYSTEM SDN BHD is committed to satisfy the requirements of its customers at all times for its products and services. An active and effective Quality Management System to the requirements of ISO 9001:2000 is maintained to support this effort. The Group has also embarked on a program to achieve the highest quality standard conforming to the ISO/TS 16949:2002 Quality Management System by the year 2006. FLEXIBLE MACHINING SYSTEM SDN BHD is committed to provide quality products and services on time at competitive costs.
Our achievements are recognized through our customers’ success, industry and customer recognitions, and successful continuous improvement programs Particulars of company Auto-Reka (M) SDN. BHD. DATE INCORPORATED: 1989 PRINCIPAL ACTIVITY:Design & development and manufacturing. COMP. SECRETARY:ACESTAHL HOLDINGS BANKER:Hong Leong Bank, Bandar Baru Rawang. Selangor. AUTHORIZED CAPI TAL:RM 300,000. 00 PAID-UP CAPITAL:RM 300,000. 00 COMPANY DIRECTORS:a) Mr. Kok Lee Yap (Managing Director) b) Mr. Kok Hong Yap (Executive Director) CONTACT PERSON:a) Mr. Henric Gan (Operation Manager) b) Mr.
Marcus Yew (Business Development Manager) FACTORY AREA:254,333 Sq. Ft and built up area 100,000 Sq. Ft. FLEXIBLE MACHINING LOGO Organization of Flexible Machinig System SDN. BHD. FLEXIBLE MACHINING SYSTEM SDN. BHD location map. Services. • Induction Hardening Process • Honing. • Grinding. • Chroming. • Manufacturing such as CNC, VMC, Welding. • Servicing of hydraulic piling equipment • Repairs of Hydraulic Rods for use in fork-lifts in container depots • Rebuilt Equipments. • Vertical Hardening Machine – EFD (VHM3500) • Horning Vertical and Horizontal Machine (NC honing machine). Grinding Machine (Danobat CNC Grinder Machine) • CNC Turning Machine (Danobat TCN-12) • VMC Milling Machine (Moire Seiki MV0-4) • Sawing (Moire Seiki SW0-3) QC equipment. • Hardness Tester. • Jigs Tester. • Precision equipment. • Profile Projector. • TRACTOR-LINE SDN. BHD [pic] Tractor-Line SDN. BHD. Tractor-Line SDN BHD is a member group of the Flexible Machining System Group, primarily responsible for the design and development, Hydraulic cylinder,And Tractor Parts. Operating at the same place as Flexible Machinind System Factory area at Bukit Rawang Jaya Industrial Center, Rawang. Tractor-Line SDN.
BHD is managed and operated by group of highly skilled and experienced workforce capable of handling high profile and complex Automotive Parts projects. Particulars of company TRACTOR-LINE SDN. BHD. DATE INCORPORATED:1989 PRINCIPAL ACTIVITY:design and development COMP. SECRETARY:Aeshstar Sdn Bhd. BANKER:Hong Leong Bank, Bandar Baru Rawang. Selangor AUTHORIZED CAPI TAL:RM 300,000. 00 PAID-UP CAPITAL:RM 300,000. 00 COMPANY DIRECTORS:a) Mr. Kok Lee Yap (Managing Director) b) Mr. Kok Hong Yap (Executive Director) CONTACT PERSON:a) Mr. Henric Gan (Operation Manager) b) Mr. Marcus Yew (Business Development Manager)
FACTORY AREA:254,333 Sq. Ft and built up area 100,000 Sq. Ft. Organization of Auto-Reka Tooltech SDN. BHD. TRACTOR-LINE SDN. BHD location map. [pic] ACESTAHL SDN. BHD Auto-Reka Gedung Tinggi Industri SDN BHD. ACESTAHL Sdn Bhd is responsible for all the account and finance of Tractor-line Sdn Bhd and Flexible Machining System Sdn Bhd. Other than that, this company also responsible for the administration all of his group members. This company is controlling the human resource department and resource and development department,l also the marketing department. More importantly, this company is the head of all group company.
Particulars of company ACESTAHL SDN. BHD. DATE INCORPORATED:1989 PRINCIPAL ACTIVITY:Finance,marketing and Resource development and Human Resources. COMP. SECRETARY:ACESTAHL HOLDINGS. BANKER:Hong Leong Bank, Bandar Baru Rawang. Selangor AUTHORIZED CAPI TAL:RM 300,000. 00 PAID-UP CAPITAL:RM 300,000. 00 COMPANY DIRECTORS:a) Mr. Kok Lee Yap (Managing Director) b) Mr. Kok Hong Yap (Executive Director) CONTACT PERSON:a) Mr. Henric Gan (Operation Manager) b) Mr. Marcus Yew (Business Development Manager) FACTORY AREA:254,333 Sq. Ft and built up area 100,000 Sq. Ft. Organization of ACESAHL SDN. BHD.
ACESTAHL SDN. BHD location map. ACESTAHL Industries SDN BHD Facility of ACESTAHL SDN BHD The main of admin building is located in the middle of factory area to simplify the admin process. This is the place or area, where all the management company that has been done with the sophisticated building design. Left Wing Ground Floor • Prayer Rooms – One prayer room each for male & female employees • Medical Centre – In-house clinic and resting place for sick employees • Restrooms – Restrooms for male & female employees. • Smoke room – place for the workers for smoking, near the guard house. Meeting room- place for discussion. • Engineering room- place for resource and development group. • Quality Control room- place for inspection and measurement instrument room. . Company organization ( Flexible machining system) This organization chart is distributed to 3 important portions which are Business, Finance & Admin and Manufacturing: ? Design & Development With the utilization of automatic ‘computer-aided design’ (CAD) and ‘computer-aided machining’ (CAM) software, from programming to process drawing, the amount of time spent on developing a finished product from initial concept has been effectively reduced.
In addition, other advantages such as great accuracy and error-free are dramatically enchanced, resulting ultra superiorty and perfection in every product designed and manufacturing. ? Finance, marketing & Admin It is more to the company financial. It is the most important in this company because this department will make sure the financial grow under financial management. Besides that the financial have to ensure the company well progress. This is because the good management shown the quality of production. ? Manufacturing
It is a one-stop center combining complete machining, designing, fabrication, welding, re-engineering, rebuilding of hydraulic cylinder group, hard chrome plating, polishing, grinding, induction hardening, honing, and testing capabilities and services all under one roof. HARDENING SERVICES Flexible Machining System Sdn Bhd being full services of design, fabrication and Manufacturing. Hardening Process. Machine: Vertical Hardening Machine -(VHM3500) A Corrugated Roller (500mm DIA x 600mm length) being hardened Capacity: 700mm DIA x 3,500mm length
Hard chrome plating . |Environmentally Friendly Chrome Plant which boast a zero discharge and total recovery system. | Capacity: Tank 1: 6′ length x 6′ wide x 10′ depth Tank 2: 4′ length x 4′ wide x 14′ depth Specification: Hard chrome plating to the federal specification QQ-C320-B Class II engineering plating / Electroplated coating of chromium for engineering purposes. Honing of hydraulic cylinders Honing of hydraulic cylinders for Steel Mill Machine: NC Honing Machine Capacity: 500mm DIA x 3,500mm length Precision cylindrical grinding Grinding of crown rollers were sent overseas to be completed.
Now, such grinding can be performed at Production facilities Machine: DANOBAT CNC Grinder Machine Capacity: 620mm DIA x 5,000mm length Rebuilt truck Case 580g LOGGING TRUCK Kenwood Logging Truck Service of hydraulic piling equipment Repairs of Hydraulic Rods for use in fork-lifts in container depots. Rod Size 114MM DIA X 7112MM Length Product In Auto-Reka Tooltech SDN BHD ARTTSB is aim to serve its customers with highly reliable design and fabrication of Parts, Bracket, Bush and Pin for automotive industries. The example of the product:- MACHINING OF PRODUCTION PARTS • Rollers. • Idler pulleys, Compressor clutch pulleys Compressor mounting brackets • Pins – Track pins, bucket pins, king pins • Undercarriage components, idler shafts, track adjusters, hydraulic tubes ? Buckets, track bushings, buckets bushings • Log forks, buckets, flange, strips, hydraulic rods • Cage, water pumps • Track link Quality in Flexible Machining System SDN BHD. Definition Of Quality ? Useful product and system ? Fill costumer contentment ? No problem in system and product Why It Is Important? ? If it has no quality in product, the business cannot go on. This is because the costumer will see the quality of the product first. How To Clarify The Quality? Understand the procedure and work instruction before start the new work. ? Use and keep the material and product at the safety place that will be guard with the security. ? Use the right document ? Keep the working place clean. ? Make the Bill Of Material (BOM) and Engineering Memo (EM) as reference Supply Chain Management ? Turnkey Project Management ? Program Management ? Production Planning And Order Management ? Supply Base Management ? Materials Management ? International Procurement Center ? Central Procurement and Purchasing Services ? Contracts Negotiation ? Materials Cost Management Pre Manufacturing Services In Partnership with Creative Technology Limited) ? Design Engineering ? Product Development ? Test Development ? Prototyping Service ? Concurrent Engineering ? Engineering And Manufacturing Solutions ? Materials Selection Consultation ? Product/Production Consultation Manufacturing Services ? Total Manufacturing Solutions ? Turnkey Project Manufacturing ? Value Engineering ? System Integration ? PCB Assembly and Testing ? Electro-Mechanical and Mechanical Assembly Post Manufacturing Services ? Order Fulfillment ? Warehousing ? Distribution (Worldwide/Regional/Local Distribution Center) ?
Repair and Refurbishment ? Transportation and Forwarding ? Total Logistics Management Flexible Machining System targets ? To achieve excellence in : CHAPTER 3: TRAINING PROGRAM 3. 1 Introduction of department and position ? I have been send to CNC, VMC and Hardening department under Production as an assistant Supervisor. Production is responsible in produce a part or product with time that have been given, other than that, in production, quantity of product must archive with the target. FLEXIBLE MACHINING SYSTEM SDN. BHD Parts of machine setter and jig setter ? Machine Setter. ? Jigs setter. Manufacture the jigs. ? Production Setter. Machine Maintenance (MM) ? MM is a process that repairing the machine that have been broke down. ? In maintenance, firstly, we must discuss what is happen to the machine that have been broke down. Next is ask the permission from immediate supervisor to proceed with the maintenance. ? The tool for maintenance is prepared for repair the machine. as usual, the tool we keep in the tool box in the maintenance room. ? Before start the maintenance, we must shut all resource power from machine that broke down, and then, we can start proceed with the maintenance. After finish the maintenance, we must keep the tool clean, Ned and tidy, in other words, keep tool clean from oil and grease. 3. 4 Machine setter. ? As machine setter, we must do a research from drawings that have been given from Quality Control (QC) or from Other Department. We must read detail in job-sheet what process that we must set. ? After that, we can proceed the setting with preparing the tool that we need. After that we can start the setting. ? Next is, after finished setting, we can run the machine and produce the product, for the first product, we must give it to the QC for Checking.
If product is good and in tolerance, can start the production, if not we must set it again until get the actual dimension. During machine setting, Milling Machine Product Setting Manufacturing the jigs ? This is process for preparing the jigs for Mass production. ? Firstly, Designer design the jigs, next, the drawing is submitted to production for machining process. ? After the machining process, we must try it to the product example. ? If it goods, the jigs can be used for mass production and can start the production. ? The product that have been produced from the jigs, must get approval from QC department. If ok, the jigs can be used.
If not, we must repaired the jigs. ? Lastly, after get the QC approval, the Jigs Can proceed to the next process, that we called Packaging. ? Example product that using jigs. VMC PROGRAM Programs for tapping at milling machine. G91 G28 Z0; G90 G10 L2 P1 X? Y? Z? ; ; ; G0 G90 G54 X? Y? Z100. M3 S100 H1; Z 50. M8; M29 S100; (CONTROL SPEED) G98 G84 Z-? R 5. 0 F 175; (F = FEED RATE = PITCH THREAD X SPEED) X? Y? (FOR THE NEXT COORDINATE) GO G90 Z100. M9; G91 G28 Z0 Y0; M3O; CONCLUSION AND SUGGESTION Thank God again because in overall of my perception, the 12 week is enough to complete the industrial training programmed.
Although it is long and give a chance to expert in the entire department works. However, the period is fit for me to carry up some of the experience in reality working. Here, we could see how a product are been doing and understand every flow of the process. During the practical session, I had learn about the working environment and slowly understood as to why thing were the way they were. Indeed too long in time to learn anything that goes on. After twenty week I’ve been doing industrial training, I can learn how to overcome problems under pressure. It is also can help me to practice on inter personal communication.
It is consist from upper to lower (supervisor – technician – operator), from lower to upper (operator – technician – supervisor) and from the same level (among technicians) The ethics of being at engineer or technician were hard to come by grasp in the beginning seeing the sacrifice one has to make for the profession. The working environment was very conducive and neat. Everyone knew what they had to do and went around their work. In short, Industrial Training is very important to all Skill College students for realize the “Hand – On” principle. They can gain a lot of experience on industry and it can be apply when in working situation.
Lastly, I would like to give a special thanks to everyone who is involved in my industrial training such as Flexible machining system staffs, for helping and give support and information. APENDIX [pic] ———————– ? Product ? Service ? Manufacturing ? Marketing ? Quality ? Infrastructure ? Technology ? Management ? Costumer ? Partnership TRACTOR-LINE SDN. BHD. LOT 3258, JALAN 1/2, BUKIT RAWANG JAYA, 48000, RAWANG, SELANGOR DARUL EHSAN. TEL: 603 – 6092 4848 FAX: 603 – 6092 7878 Engineer HOD Mr Hans Andrew Executive HOD Ms Rozali ismail Engineer HOD Ms ZulRamli Executive HOD
Ms Mohan Singh Production planning & control department Mr Wong Ah kam Engineering department Mr Rohandran Business Support Section Mr Kumar Product engineering Mr Raymon Low Admin & finance department Ms Maria Gale Marketing Manager Ms Wong Ah Fah Group Admin & finance manager. Ms Lew Chan Executive director Mr. Kok Hong Yap Managing director Mr. Kok Lee Yap Designer Mr Chin Chan Fong Manufacturing Mr Ah Kam Admin & finance. Ms Chan QC inspection Mr Tajuddin Head Of Manufacturing Mr Kee Leng Hock Design and development department. Mr Hock Lee Yap Head Of QA Department Ms Magfirah Ahmad
Head Of admin & finance Ms Chan HOD Vacant ARTTSB Operation Manager Mr. Henric Gan Group Admin & finance manager. Ms Ruby Shanon Executive director Mr. Kok Hong Yap Managing director Mr. Kok Lee Yap FLEXIBLE MACHING SYSTEM SDN. BHD. LOT 3258, JALAN 1/2, BUKIT RAWANG JAYA, 48000, RAWANG, SELANGOR DARUL EHSAN. TEL: 603 – 6092 4848 FAX: 603 – 6092 7878 Line Leaders & Operation Mr Oliver Gale Facilities Technician Mr. Raymon Low Inventory Technician Ms Rozita Ibrahim QC inspection Mr. Khairul Anuar Mr Yusni Ahmad Document control Clerk QC Supervisor Mr. Ishak Ibrahim Production Supervisor Mr. Marcus Yew
MR/ Special Pro Exec Mr Chin Chan Fong ARMSB Operation Manager Mr. Henric Gan Group Admin & finance manager. Ms Shanon yew Executive director Mr. Kok Hong Yap Managing director Mr. Kok Lee Yap SHIPMENT PRODUCTION CHANGES OF PRODUCT DRA/DIS/MCR/ECO OPERATION DEPARTMENT Mr. Kee Leng hock WAREHOUSE SECTION Mr. Shahbudin TECHNICAL SECTION Mr. Hock Lee Yap PRODUCTION SECTION Mr. Marcus Yew QA/QC Mr Khairul and Mr Yusni. MAINTAINANCE Mr. Rohandran MACHINING Operator WI ACESTAHL SDN. BHD. LOT 3258, JALAN 1/2, BUKIT RAWANG JAYA, 48000, RAWANG, SELANGOR DARUL EHSAN. TEL: 603 – 6092 4848 FAX: 603 – 6092 7878