Done for 2nd July

7/30/2019 Done for 2nd July

1/38

NURFARAHIN BT. SALLEH | UNIVERSITI TEKNIKAL MALAYSIA MELAKA 1

CHAPTER ONE

1.0 INTRODUCTION

1.1BackgroundOmega Fabrication Sdn.Bhd is Malacca based tooling manufacturer. It was located in

Kawasan Perindustrian Krubong, Melaka and was established in 1998. At that time, Omega

Fabrication only has a few workers, departments and the operating business focus was also

different. In the early phase of company business development, Omega Fabrication only

focuses on fabricating parts. It only own milling and turning departments in production line,

but now Omega Fabrication has own grinding, EDM/wire cut, deburring, CNC milling and

CNC turning departments.

Omega Fabrication was operating in a very systematic way and aim to be more

worldwide in business. It was incorporated in Malaysia under the Company Act in year 1999

with a paid of capital of RM5, 000,000. The most important is Omega Fabrication committed

to business and cultures in pursuit ofQUALITY EXCELLENCE. As a result of continuous

commitment to business and quality excellence, Omega Fabrication has obtained MS ISO

9001:2000 certifications. The establishment was also to provide total customer satisfaction

by driving towards continuous improvement programmed in all areas of quality, service and

total cost of ownership to achieve an excellent standard that will exceed customers

expectations.

As a local based high precision tooling manufacturer, Omega Fabrication has specialized

in its operating business through four dimensions. It was precision tooling (trim and form),


2/38


precision machining (carbide), injection mold parts and jig & fixtures. It fabricates a wide

range of precision tools and parts of finest quality.

Figure 1.0: Sections in operating business

1.1.2 ISO Accreditation

Figure 1.1: ISO 9001:2000

Operatingbusiness

high

precisionmachining(carbide)

precisiontooling

(trim andform)

injectionmold parts

jig andfixture


3/38


Figure 1.2: ISO 9001:2000

ISO 9001:2000 is specifies requirements for a quality management system where

organization of company needs to demonstrate its ability to consistently provide finish products

that meet customer and applicable regulatory requirements. It also aims to enhance customer

satisfaction through the effective application of the system which including processes of

continual improvement of the system, the assurance of conformity to customer and applicable

regulatory requirements.


4/38


1.2Organizational chart

Figure 1.3: Omega Fabrication Sdn. Bhd. organizational chart

1.3Vision and Mission1.3.0 Vision

To become a reputable leader in precise tool manufacturing-Omega Fabrication vision is to be a leader in precision manufacturing and to meet global

demands for quality products in semiconductor and all high tech industries.

To provide unlimited support and services to customers in business

-Omega Fabrication also providing support and services to customer in term of operations of

business; equipments for inspection with subcontracting companies, knowledge and advice.

To improve company through ISO 9001:2000 Quality Management System

-Omega Fabrication is continually improved in ISO 9001:2000 (QMS) in order to ensure

customer satisfactions at all times.

To improve company through Quality Improve, Cost Reduction (QICR) programmed

-QICR is a programmed own and manage by Omega Fabrication itself. It is step to maintain

customer satisfaction and loyalty.

MANAGINGDIRECTOR

MANAGEMENTREPRESENTATIVE

DOCUMENTCONTROL CLERK

BUSINESSDEVELOPMENT

MANAGER

MARKETINGEXECUTIVE

ASSEMBLYTEAMS

SALES/SERVICEMANAGER

PRODUCTIONMANAGER

TURNINGSUPERVISOR

MILLINGSUPERVISOR

WIRE CUT/EDMSUPERVISOR

GRINDINGSUPERVISOR

DEBURRINGLEADER

CNC MILLINGSUPERVISOR

CNC TURNINGSUPERVISOR

QUALITYASSURANCEEXECUTIVE

PLANNINGEXECUTIVE

STORE ANDDELIVERY

COORDINATOR

QUALITYASSURANCESUPERVISOR

FINANCE ANDACCOUNTOFFICERS

DESPATCHASSISTANT

PURCHASINGOFFICER

HUMANRESOURCE

OFFICER

GENERALMANAGER


5/38


1.3.1 Mission

Omega Fabrication Sdn.Bhd. mission is to continuously grow and improve in partnership

with customers to provide quality, delivery, competitive price, service and support and

customer satisfaction at all times.

Omega Fabrication Sdn.Bhd always focuses to identify customer need through continual

technological improvement and open continual communication. They always put on

believes with customer-supplier relationship and continually striving for improvement in

quality. Therefore, they always at high expectation to provide customer with cost

effective, on time delivery with excellent service and support.

1.4Quality Policy

Figure 1.4: Omega Fabrication Sdn. Bhd. quality policy


6/38


1.5Competitive advantageI have defined Omega Fabrication Sdn. Bhd. competitive advantage into four sections. The

competitive advantages are quality, machinery, capacity and competency.

(A)QualityOmega Fabrication Sdn. Bhd. always aims and provides customer with the highest

and finest quality products as it is the local based high precision tooling manufacturer.

It fabricates a wide range of precision tools and parts of finest quality. As a proved

Omega Fabrication Sdn. Bhd. has customer from a widen industrial sectors such as

semiconductor sector, energy or oil and gas sector, aerospace sector, industrial

automation sector, shipping sector and precision engineering sector.

(B)MachineryOmega Fabrication Sdn. Bhd. always focuses to identify customer need through

continual technological improvement and open continual communication. Therefore,

the machinery provide in the production line in every departments such as milling,

turning, deburring, EDM/wire cut, grinding, CNC milling and CNC turning

departments are all high technology machineries. Further, the machineries provide in

quality assurance departments are also high technology machineries. It is to support

Omega Fabrication Sdn. Bhd. motto, Quality is our priority.

(C)CapacityAccording to Omega Fabrication Sdn.Bhd. mission, continuously grow and improve

in partnership with customers to provide quality, delivery, competitive price, service

and support and customer satisfaction at all times. Therefore, I found that every day

store and delivery coordinator and quality assurance supervisor set and manage the

outgoing of finished products to deliver to customer. Then, planning executive and

quality assurance executive also paid their responsibility to make sure and maintain

the capacity of outgoing finished products should be done every day is achieved. This

is because Omega Fabrication Sdn. Bhd. always served customers with delivery on

time.


7/38


(D)CompetencyOmega Fabrication Sdn. Bhd. also has many technical expertises which are very

competence to their quality of work. Even though, some of the operators are hired

from Myanmar, Indonesia and Nepal, but they are very competence to their work too.

This is because all of them are really understand and focuses to company visions and

missions.


8/38


1.6Business process flowCUSTOMER

BUSINESS

DEVELOPMENT

PLANNING

PURCHASING/STORE

PRODUCTION

SUBCON

QUALITY

ASSURANCE

CHECK

ACT

Figure 1.5: Business process flow

Customer

enquiry

Customer

receive

quotation

Deliver to

customer

Customer

issue

Purchase

order (PO)

Prepare

quotation

Review order

Resources Resources

planning

Order

materials/parts

Check stock Store Prepare

invoice

Production

Heat

treatment/finishing

treatment

QA in process

check

QA incoming

control

QA final

inspection

Packing

Internal audit

Management review

Continuous

improvement

YES


9/38


CHAPTER TWO

2.0 THE INDUSTRIAL TRAINING PROGRAMME

2.1 Scopes of responsibility

During my training session in Omega Fabrication Sdn Bhd, I have been located in

Quality Assurance (QA) department which comprises with quality control team. Along this

experience my major job scopes was to generate quality assurance finish product inspection

report and key in data of the outgoing products in the system.

Here, I have found that quality is not the responsibility of any person or only for QA

department, but it is everyones job. From the theory in Quality Management subject, I learnt

that areas responsible for quality control are marketing, design engineering, procurement,

production, process design, inspection and test, packaging and storage and customer. Therefore,

from the issues rise in QA department which will be discussed in Chapter 4, I concluded that

quality of finish products was not only the roles of QA department but also every department

should play their roles to maintain and make sure the finish products were in good quality.

I have seen that quality assurance does have the direct responsibility to continually

evaluate the effectiveness of the quality system and it also determines the effectiveness of the

system, appraises the current quality, determines the quality problem areas or potential areas and

assists in the correction or minimization of these problem areas. In my opinion, the overall

objective of QA department was the improvement of the quality in cooperation with the

responsible departments. Below is QA finish product inspection report form.


10/38


Figure 2.0: Diagram of Quality Assurance finish product inspection report form

The most important I have learnt in written the QA finish product inspection report form

was about dimensions, sampling size, instruments used, tolerances and treatment processes. For

dimensions, I should be able to recognize whether the dimensions were controlled or non-

nstruments used

Dimensions

Sampling sizeTreatmentProcesses

Tolerances


11/38


controlled and learnt many symbols of dimensions in the technical drawings. For sampling size, I

had to determine the sampling size with the given quantity of finish products. It just like what I

have learnt in Business Statistics subject. Below is the sampling plan that I was dealing with

every day.

Figure 2.1: The sampling plan of QA finish product inspection report

The purpose of sampling size was to determine the number of finish products need to be

inspected if finish products were too many. For tolerances, I had to calculate and make sure the

actual measurement of finish products from the inspection were in specs. If the actual

measurements were out of specs, I needed to remind and alert to the quality control inspector.

Others, for controlled dimensions, I needed to use Information Tolerances Tables to calculate

and make sure the actual measurement from the quality control inspector was in specs. The

Information Tolerances Tables were including with x-axis and y-axis. The x-axis was the ISO-

symbol and the y-axis was the nominal. The most important I have learnt from it was the

calculation of dimensions based on the technical drawings.

For treatment processes I had opportunity to learnt a lot about finishing, harden andmaterial. Here, I had viewed and got a lot of information of finish products which undergone for

types of finishing and harden processes from different materials. Below are finish products that

undergone for treatment processes; white zinc and electroless nickel.


12/38


Figure 2.2: finishing; white zinc

Figure 2.3: finishing; electroless nickel

Finally for instruments used, I learnt about the correct checking method for finish

products which comply with requirement. It really complied with my Manufacturing Process


13/38


subject. First, I learnt how to measure the dimensions of diameter which complied with

requirement. For controlled hole diameter, 0.5mm to 20.01mm was needed to use pin gauge,

20.01mm to 50.01mm was needed to use bore gauge, 50.01mm was needed to use smart scope,

coordinate measuring machine (CMM) and 0.4mm was needed to use smart scope. For outer

controlled diameter, 0.001mm-150.00 mm was needed to use micrometer (clamping test) and

150.01mm was needed to use CMM. For non-controlled diameter was needed to use caliper. For

dimension, internal controlled distance 0.005mm to 200.00mm (slot) was needed to use block

gauge and distance from 0.005mm to 600.00mm was needed to use height gauge or CMM. For

dimension, external controlled distance was needed to use smart scope, height gauge and CMM.

For non-controlled dimension was needed to use caliper. For flatness or parallelism was needed

to use dial test indicator. For checking screw was needed to use fitting test according to the size

and depth. For normal thread or special thread was needed to use thread gauge and fitting test

according to the thread. For angle and radius was needed to use protector, smart scope and

CMM. For treatment the confirmation must certified with certificate of compliance.

I was also dealing with the certificate of compliance for customers which were the

certificate of compliance from finishing process, certificate of compliance of hardened process

and material certificates. Normally, every week I was needed to recognize, separates and filing

the hardened, finishing and material technical drawings completed with its inspection report to

scan and key in the outgoing finish products data according to customer purchase order number

and date. The requirements needed to send the inspection report and certificate of compliance to

customer was only for two days. Therefore, it was my responsibility to keep in touch and deal to

customer with the inspection report and certificate of compliance. The inspection report was very

important as it was customer requirements where it would be as a reference for both if any

troubles raised to the inspected finish products after it had been delivered to customer.

Meanwhile, the certificate of compliance function was as a proved to customer that the finish

products had undergone treatment processes; finishing, hardened and material.

My minor job scope was checking simple finish products. I was not be able to check

complicated finish products due to time frame obstacle which there was a lot of urgency finish

products need to be inspected every day. But the QA team always gave me added information

especially in inspected the complicated finish products. It was especially the symbols and metrics

which include the first, second and third view of the technical drawings. This was really added


14/38


information for me because I have not learnt Technical Drawing subject before but I was very

interested at it as I was dealing with it along this six months of training sessions.

Furthermore, I learnt about the instruments used in checking finish products and its

correct checking method. This was applied with the theories I learnt in Manufacturing System

subject which included the instruments used in checking the finish products. The instruments

available in QA department were analog vernier, dial indicator, digital vernier, smart scope, pin

gauge, micro meter, dial caliper, block gauge, height gauge, fitting test, CMM and bore gauge.

Below are the pictures of equipments for inspecting finish products.

Figure 2.4: digital vernier caliper

Figure 2.5: bore gauge


15/38


Figure 2.6: micro meter

Figure 2.7: block gauge

Figure 2.8: fitting test


16/38


Figure 2.9: smart scope

Figure 2.10: coordinate measuring machine


17/38


Figure 2.11: height gauge

Finally, regarding to my job scopes which key in data in systems. My routine was also

key in data and recorded the number of outgoing products. The system used for this job scopes

was Automated Business System. It complied with my Management Information System subject

whom nowadays many companies used significant systems to easily manage and operate its

businesses. This was very important because by key in the outgoing finish products data the store

and delivery coordinator and the planner of company were easily coordinate and target monthly

sales performance. The data were comprises with customer purchase order number, technical

drawing part number, delivery date, types of materials, weights and quantity.

2.2 Important and significant of my responsibility to the organization.

Regarding to my job scope generating QA finish product inspection report was very

important as it was customer requirements when delivering along with the inspected products.

This was because when something defected was determined, so customer would refer to the

inspection report. Therefore, my job scope was very important as I was also responsible to

maintain companys status. Finally, the inspection reports were also needed for achieving


18/38


19/38


CHAPTER 3

3.0 INDUSTRIAL TRAINING ASSIGNMENTS

My industrial training assignments at Omega Fabrication Sdn. Bhd. Quality Assurance

Department are to generate quality assurance finish product inspection report, key in data in

computer and dealing with certificate of compliance and inspections reports for customer.

For the first task is generating quality assurance finish product inspection report. I would

like to enlighten that generating quality assurance finish product inspection report is not an easy

task. The strongest reason is because this inspection report would be as reference for customer if

any problems occur with finished products. The problems usually occur such as dimension

problems which comprises with the controlled and non-controlled dimensions, finishing and

harden problems and materials. In my opinions, generating quality assurance finish products

inspection reports is a big responsibility as I am also bring the company s name and status to

customer. In Omega Fabrication Sdn.Bhd. also have a very worldwide customer which they are

from Europe, South East Asia, Japan, Dubai Emirates and Malaysia. Therefore, I am also

involving myself with the worldwide customer.

According to ISO 9001:2000 Requirements Mandatory Procedure, it comprises the

elements; control of documents, control of records, internal audits, control of non conformity

products, corrective and preventive actions. Regarding to my daily task, the quality assurance

finish product inspection reports are also called as control of documents for auditing with

International Organization for Standardization. Usually the audit session will be held once in the

ends of the year. Before I explain more on my task, generating quality assurance finish product

inspection reports, I would like to explain about the operational quality control checking flow.

Operational quality control checking flow is guidance for quality control inspectors in doing

their responsibility to check the finish products. Below is the operational quality control

checking flow that quality control inspectors used in Quality Assurance department.


20/38


Figure 3.0: Operational Quality Control checking flow

In operational quality control checking flow, first, QA department received part for

inspection session from production department. Usually, before the Head of Department dividingpart received to quality control inspectors for checking, I would update the daily output products.

Daily output products means the total number of parts need to be checked and had been checked

in QA department. After completed updating the daily output products, the Head of Department

was dividing the parts to quality control inspectors. Second, once parts received to quality

control inspectors, they need to check the quantity of the parts as required in the technical

drawings. Third, they need to check the material used is as indicated in the technical drawings.

Fourth, they need to check the finishing parts such as surface finishing; electroless nickel, clear

anodize, hard chrome, flash chrome and chemical passivation and harden; HRC 58~60 and

709/760 nitri hard. Fifth, they need to study the dimensions in the technical drawings and

recognized the controlled and non-controlled dimensions. Here, they need to use the correct

equipment as indicate in the checking method.

1. PART RECEIVED

2.CHECK QUANTITY

3. CHECK MATERIAL

4. FINISHING

5. DIMENSION

6. INSPECTION REPORT

7. APPROVAL

8. PACKING


21/38


Sixth, is the part whereby it is my responsibility to generate the quality assurance finish

product inspections reports. I need to transfer the entire inspected dimension to the inspection

reports and I must to make sure that all the dimensions is in specifications as required in the

technical drawings. In my opinion, generating the quality assurance finish products inspection

reports is an added value for me as I am learning a lot in the equipment used for the right

checking methods, symbols in the technical drawings and I am able to know and use the ISO

tolerances effectively and efficiently. This is really a very valuable knowledge for me. Seventh,

after the inspection report is completed, final approval of inspection from the Quality Manager is

need before all the parts send for packing. Finally, was the packing session.

My responsibility is not just generating the inspection reports, but I must alert with the

requirements in the technical drawings and customer. The requirements are such as the materials

certificate, certificate of compliance of hardening and treatment processes. This certificate is

send as a proved for customer. Others, generating the inspections reports also create me to be a

responsible person by whom I need to aware the quality control inspectors if the inspected

dimensions were not in the range of specifications. In my opinions, generating the inspections

reports was the risky tasks for me. This because I am also will be the important person if any

problem occurs to the parts send to customer.

According to Besterfield (2008) has state that Quality Function Deployment is a system

that identifies and sets the priorities for products, services and process improvement

opportunities that lead to increased customer satisfaction. Regarding to my task I am also

involving myself in completing the non-conformity report from customer. After the quality

control inspectors had discussions among them about the problem assigned in the non-

conformity report, then, the head of department will explained and discussed to me how to

complete the non-conformity report. Usually, I am key in data of the corrective actions for non-

conformity report and send it to customer e-mail. In my opinion, the quality function deployment

process creates good relationships for both customer and supplier and it leads to increased

customer satisfaction. This is because quality function deployment ensures the accurate

deployment of the voice of customer throughout the product planning to field of service.

According to my opinion, in serving the best quality for customer, not only one department

responsible to give the best quality of work but all the entire departments in company should


22/38


paid their good responsibility to provide goods and services that meet or exceed customer

demands.

Below is the operational quality control flow chart. This flow chart shows clearly which

parts should be delivered to customer and keep in store.

Figure 3.1: Operational Quality Control flow chart

PART RECEIVED IN

OQC

SEGREGATION

REWORK/REMAKE

NEW

COMPLETE PROCESS

GREENSTICKER

CHECKING

PACKING

ISSUE QA REJECT

REPORT

CUSTOMER

QC REPORT LABEL

CUSTOMER P.O

STORE

UPDATE STOCK AND

STICKER

INCOMPLETE

PROCESS ORANGE

STOCK

QC REPORT

VERIFICATION

NO

YES


23/38


24/38


assurance, improve my communication skills and also give me wide experience about

equipments used in quality control.


25/38


CHAPTER 4

4.0 INNOVATIVE SUGGESTIONS

Regarding to my job scopes is to generate quality assurance finish products inspection report and

handling certificate of compliance and inspection report for customer, here I come out with

several suggestions. My purpose to come out with these innovative suggestions is to give ideas

for my Quality Assurance department and also the entire company in order to have a better

quality management system.

Problem 1: Problem in filing documents for ISO

The International Organization for Standardization has developed ISO 9001:2000 as a

means for company to institute quality management systems through a set of controlled

procedures and practices. ISO 9001:2000 also specifies requirements for a quality management

system where an organization needs to demonstrate its ability to consistently provide product

that meets customer and applicable regulatory requirements and aims to enhance customer

satisfaction through the effective application of the system including processes for continual

improvement of the system and the assurance of conformity to customer and applicable

regulatory requirements. The purpose of ISO 9001:2000 standards is to promote the habit of

evaluating operational processes and it fundamental principle resides in working through process

improvement to achieve product quality. Omega Fabrication Sdn. Bhd. also has accredited and

certified with the requirements of ISO 9001:2000. Therefore , according to ISO 9001:2000

Requirements Mandatory Procedure, which comprises the elements; control of documents,

control of records, internal audits, control of non conformity products, corrective and preventive

actions, Omega Fabrication Sdn. Bhd. had done well all these elements to meet the ISO

9001:2000 requirements mandatory procedure.

But along the training session, I have viewed that the employees does not have anyproper way for filing all the technical drawings and quality assurance finish products inspection

report. Currently, they used a traditional way to keep and store all the technical drawings and

inspection reports. These technical drawings and inspection reports need to be kept and stored

safely as well as for an external audit. External audit is comprised of a Second Party Audit and a

Third Party Audit. The Second Party Audit is normally performed by customer such as the


26/38


supplier and the Third Party Audit is performed by registrar such as independent audit. The main

purpose of the auditor is to validate the documentation and make sure the employees are properly

trained to do their jobs. Therefore, in my opinion by practically used this traditional way to keep

and store all the important documents for external auditing session soon, it might be raised some

problems for company. Why I say so is because I have viewed all the technical drawings with

inspection reports are kept in a store room within plastics bags and paper boxes. Besides, there is

also bulky of technical drawings with inspection reports that have not been filing on the floor in

the store room.

In my opinion, the traditional way of filing these documents is really not in a systematic

way whereby in these modern era, effective organizations should choose a very systematic way

in managing all the entire things in the company. Here, I am come out the innovative suggestions

not to complain the way of Omega Fabrication Sdn. Bhd. filing and preparing for external audit

session but I am here to give my ideas just to make the way of filing of all documents is in

effective way and can be accessible easily. There are several reasons why I say the current way

of filing is not effective. First, I imagined 10 years later, the store room will full with bulky of

documents. Second, the way to kept all the documents just in the paper boxes in the store room

really exposed to danger which is if disasters happened such as flood, fire or else the documents

are exposed to pests such as termites, so, there is no secure back-up and the documents will

damaged beyond repair. Third, it is a long time consuming when need to retrieve the documents

in emergency cases. Fourth, the documents now would not be accessible and untraceability and

finally, this traditional way of filing are unsecure because documents can be easily lost.


27/38


Solution for Problem 1: Document Management System

Figure 4.0: Components of Document Management System

According to this cases, I suggest that Omega Fabrication Sdn. Bhd to implement a

Document Management System for filing. Document Management System is any software that is

used to provide an efficient manner of collecting documents, storing them and making retrievaleasy. The benefits of implementing this system are many. First, it improves employee

efficiencies by eliminating the manual processes and also leading to improved information,

increased productivity and better process consistency. Second, it promotes flexible documents

retrieval which is less time is spent for locating the documents as they can be retrieved the

documents without leaving the desk. Other, Document Management System also very flexible as

the users can also access other systems as retrieving the documents. Compared to the traditional

way employees need to spent much time for finding the documents from the storage especially in

emergency cases and it becomes the situation more worst. Third, no more lost documents which

are losing technical drawings and inspection reports usually make trouble for my quality

assurance department team as they need to deal and serve customer on time in order to gain

customer loyalty. Fourth, it will be as disaster recovery strategy. In my opinion paper is a bulky

and expensive way to back-up records and also is vulnerable to fire, flood, vandalism, theft and

RETRIEVAL

STORAGE

LOCATINGAUDITING

INDEXING


28/38


finally it will improved security as it can provide better, more flexible control over sensitive

documents.

What are Document Management System requirements?

According to MacKechnie (2003) state that Document Management System are changing the

way of organizations store and retrieve documents and replaced the old-school files and cabinets

with new and high technology tools. By referring to Omega Fabrication Sdn. Bhd. traditional

way in filing the technical drawings and inspection report, usually the employee took a very long

time for arranging all the technical drawings. One of the way in arranging the technical drawings

and inspection report are by following the job number of the drawings manually.

Therefore, the requirements of Document Management System are scanner, document

management software and storage device. First, the scanner will be function as to scan all the

technical drawings and inspection report that completely undergoes inspection session. Second,

document management software that drives the Document Management System. Document

Management System is only as good as the software that drives it. Third, storage device which is

range in size and functionality.

How the Document Management System works for filing?

Figure 4.1: Sample workflow of filing


29/38


Once the technical drawings are completing with the inspection reports, first it will be

send to customer as requirements from them. Then, the technical drawings and inspection reports

are scanned to run in the data in Document Management software for filing. The documents will

be run in the classification system which are refer to the customers name, job number or

purchase order number. After that, data will be circulate in the system which the technical

drawings and its inspection reports are available for certain departments in Omega Fabrication

Sdn. Bhd. such as Quality Assurance Department and Store & Delivery Finished Goods

Department. Therefore, if any problem occurs such as non-conformity reports raised from

customer after delivery the finished products, so the problem will solve immediately in action

whereby the documents can be retrives as soon as posible by using Document Management

System. Compare to the current way of filing the technical drawings and its inspection reports,

usually the employees take longer time to retrieve the documents. The effieciency of productivity

also can be improved as customer satisfied with the services company has served. Others, by

using this system staffs in department can simply forward the documents among the team

department as they did not need to move around for discussion the problems and the percentage

of lossing the technical drawing and its inspection report also decreased. In conclusion, everyone

can paid their efficiency and effective way of working environment as the system are enabling

instatnt access to documents.

For external auditing session, by implementing Document Management System, the way

of filing all the technical drawings and its inspection reports will look more systematically and

organized.

Figure 4.3: Current way of filing Document Management System


30/38


Problem 2: Internal design in Quality Assurance Department

In my opinion the internal design for Quality Assurance department is not too comfortable for

quality assurance team working environment. The reason is because all the equipments for

inspecting the products are kept in one room with the entire workers table. Below is the sketch of

my Quality Assurance department.

Figure 4.4: Sketch of Quality Assurance department room

Solution for Problem 2: Separate the room of equipments

My suggestion is Omega Fabrication Sdn. Bhd. need to separate the room of equipments or

inspection parts and the room of workers. My strong reason is normally sometimes the lossing of

finished products and its technical drawings is because the room of quality assurance department

is full of urgent products that need to be inspected. From my experienced along this training

session, the situations in my quality assurance department becomes more trouble when there is

Workers table

Height gauge

CMMSmart scopeRack of files

Others

equipments,

computers,printer

Workers racksFinish products signature

part


31/38


many urgent products located in department and each of the products need to inspect carefully.

In my opinion, eventhough it is much costly to change the internal design, but for a long term

vision its quite gives more benefit to company profitability and productivity. Moreover, I think

with this innovative suggestion, the situation for inspecting the finished products will be more

organized, strategically and the number of non-conformity reports can be reduced.

Problem 3: Increasing of non-conformity reports (NCR)

Non-conformity reports are reports which issued when finish products, processes or procedure

does not comply with the set standards for particular belongings to the finish products, processes

or procedures under inspections. According to Besterfield (2008) has state a Cause and Effect

diagram is a picture composed of lines and symbols designed to represent a meaningful

relationship between an effect and it causes. Therefore, I have defined the increasing of non-

conformity reports by using Cause and Effect diagram advocated by (Ishikawa,1982 ).

Figure 4.5: Cause and Effect diagram of increasing of NCR

INCREASING

OF NCR

MATERIAL METHOD

MACHINERY ENVIRONMENT MEASUREMENT

MANPOWER


32/38


Solution to Problem 3: Materials, environment, method, manpower, measurement and machinery

There are six causes that caused the increasing of NCR. For materials, sometimes the materials

used in producing the requested products from customer would not be able to be inspecting from

quality assurance team. This is because the materials properties are much sensitive and are not be

able to be inspecting with the equipments. It might be because the planner and production lines

want to follow and meet customer requirements but they were less thinking about the ability of

quality assurance team during inspecting the products. According to this situation, I suggest that

before accepting customer order, the planner should study the technical drawing and

requirements from customer first and understand carefully whether all departments have their

ability to run out the products as they can pay 100% responsibility to increase the company

profit.

For environment, I found that the temperature in my department is cold. It is about 21

degree Celsius. The reasons are to keep the CMM machine, height gauge and smart scope in

good condition. All these expensive equipments need to be in cold condition. Therefore, these

cold temperature will cause some of materials of finish products been shrink and it will cause my

team to get inaccurate measurement result during inspection session. According to the situation

had happened, which customers have complain that they have different measurement of

inspection result compare to my team measurement of inspection result. This is because the room

temperature where finish products been stored also influenced the measurement of inspection

results. According to this situation, I suggest all the finish products that come from the

production department must be stored in one room which the room temperature is in normal

room temperature. Meanwhile, all the equipments use in quality assurance department must be

placed in one room which these equipments need to stay in cold room temperature.

For method, I found that error easily occur everywhere. First, from the inspection

sessions my team detected missing process by production department. Second, error occursduring the inspection time such the inspector forgets to inspect some dimension which is control

or non-control. Third, error occur during writing the quality assurance finish product inspection

report as there are many dimensions of complicated technical drawings need to be written.

Fourth, my company got complains from customer as we deliver more or less finish products

differ from the customer purchasing order record. All these occur because of human limitations


33/38


as they need to inspect many products in a day and feel of tiredness. According to this situation, I

suggest that everyone in this company should always practice and follow the quality

management vocabulary which is doing it rights at first time and always be responsible with

the tasks they need to complete.

For manpower, in my opinion, the number of workers in my quality assurance

department is not enough to handle all the urgent products that need to be inspecting in a day.

Due to situations that I also faced during writing the quality assurance finish products inspection

report, I need to do many of inspection reports in a day. So, time planning and time management

is very important every day. Every day I found my quality assurance team will be rushed to

complete inspecting all the urgent products and usually they need to do overtime working hours.

Therefore, the workloads for them in a day are high and it will decrease their focus on

completing all the tasks given. According to this situation, I suggest my company to hire new

workers with high skill and experiences in using the equipments in quality assurance department

or another solution is to do shift working hours rather than practice normal shift working hours

as usual now.

For measurement, in my opinions some of my quality assurance team is lack of training

in inspecting the complicated finish products. This is due to situation happened which not all my

quality assurance team is able to inspect the complicated finish products. Complicated finish

products mean finish products which have a lot of dimensions, big sizes and complicated shapes.

Some of them are also lack of skill to use the equipments such as CMM machine. So, other team

members need to help the one who lack of skill in inspecting the finish products. This will cause

trouble and lack of focus of other team members in inspecting their finish products as there are

many urgent finish products need to be handled every day. The most important that I want to

enlighten here is about technology readiness which I have found that some of quality assurance

team members are not well-adapted with the high technology equipments. According to this

situation, I suggest that my quality assurance team members should attend several courses of

training which would make them very adaptable with all the high technology equipments provide

in quality assurance department.

Finally, for machinery in my quality assurance department are all high technology

equipments. Usually high technology equipments are very costly. Based on what I have learnt


34/38


before in Microeconomics subject, usually organization need to minimize cost and maximize

profits. Therefore, in this situation I understood why there are only few high technology

equipments provide in my quality assurance department but in my opinion I have seen these few

high technology equipments as a problem in handling all the urgent finish products every day. I

think my quality assurance department is lacking of inspection equipments. The reasons are

because my quality assurance team members usually need to queue among them in inspecting the

finish products. The situation becomes very trouble if there are many urgent products which need

to be inspecting by using the same equipments.

Therefore, once my quality assurance department received non-conformity report from

customer, the first solution that usually they do are discussing among them whether they should

take preventives or correctives actions regarding to the problems stated in the non-conformity

reports. The ways to solve the non conformity reports can be variously as it depends on the

problems occur. Once they have decided the solutions, they will let customer know the cause of

problems occur and also let them know whether to take correctives or preventives actions.

From this issue, I observed the non-conformity report really related to the ISO 9001:2000

requirements mandatory procedure. The requirements mandatory procedure are;-

(A)Control of documentsControl of documents is the finish products inspection reports that usually my department

releases with the outgoing of finish products after it completing the final inspection.

(B)Control of recordsControl of records is recorded data of outgoing finish products by using the Automated Business

System and the recorded data of rejected parts after it releases from production department and

undergoes the inspection sessions.

(C)Internal auditsUsually the internal audits will occur once a year. This to enhance the finish products always

meet customer satisfactions and company business operations is following the ISO 9001:2000

certifications.


35/38


(D)Control of non-conformity productsControl of non-conformity products is measurement of organization to handle the non-

conformity products such as training in using the high technology equipments in inspection.

(E)Corrective actionAction takes when problems occur.

(F)Preventive actionAction should be aware from repeating the same problems.


36/38


CHAPTER 5

5.0 CONCLUSION

In conclusion, this industrial training gave me a lot of experienced and precious of

knowledge. Along these six months in Quality Assurance department I have gained a lot of

information and knowledge which much related with my Bachelor Degree in Technology

Management and Innovation. I also have gained much add-up knowledge such as learning a lot

in technical drawing especially the symbols and the equipments used in inspecting the products.

The working environment also teaches me a lot that time management and strategic planning is

very important in paying our responsibility to company. Others, this industrial training gave me

opportunity to explore more on the theories that I have learnt in Bachelor Degree in Technology

Management and Innovation. I am really appreciating this experience which I am able to know

the reality lives of working in an industry. In my opinion, working in an industry really

challenges me and my abilities to adapt with working environment which sometimes it become

so much stressed but in the end I know this is really a precious moments. I am also learnt to be a

more responsible person as I am doing my job scopes and able to come out with my innovative

suggestions. These experiences really make me feel theories are easy to be learnt but it is

difficult to implement if there is no discipline and responsibility in everyones selves.

5.1 Bachelor Degree Dissertation

For Bachelor Degree Dissertation I would choose a topic on clean technologies innovation and

introduction. I am very interested at this topic because I am really eager in learning technology

innovation subject and it is my hobby to explore and knowing on the latest technology.

Moreover, nowadays I see pollutions problems occurred everywhere. There are many

types of pollution occurred such as air pollution, water pollution and sound pollution. As we

know these pollutions would disturbed and harmed human lives and activities. Regarding toclean technologies, I am interesting in exploring and researching in preventing the air pollutions.

At this time, I got the idea either in upgrading the current clean technologies or else in

introducing the new technologies in preventing the air pollutions. In this modern era, we have

many air cleaning technologies such as industrial vacuum systems, industrial dust collectors,

asphalt smoke control, portable air cleaners, woodworking dust collection and restaurants


37/38


exhaust. Therefore, by exploring more on this topic I hope I can upgrade or introducing a new air

cleaning technologies.

My objectives to choose on clean technologies innovation and introduction are first, I

would like to challenge myself in exploring and researching the new air clean technologies.

Second, I would like to provide the minimal level of air pollutants and third, I would like support

The Ministry of Science, Technology and Innovation, Malaysia objectives to enhance the

capability of technopreneurs to increase industrial competitiveness through technology transfer.

Thus, I would choose Dr. Chew Boon Cheong from Faculty of Technology Management and

Technopreneurship as my supervisor for Bachelor Degree Dissertation.

The most important thing that I can relate with my experienced along the industrial

training in Quality Assurance department is quality is not just responsibility of any one person,

but it is everyones job. It is same as the topic of clean technologies innovation and introduction

which we as people in this world must paid our responsibility to the world to create and innovate

the cleaning technologies to maintain good quality of lives.


38/38

REFERENCES

1. Russel, R.S. and Taylor, B.W., 2011. Operations management. 7th ed. United Statesof America: John Wiley and Sons, Inc.

2. Robbins, S.P. and Coulter, M., 2009. Management. 10th ed. New Jersey: PearsonEducation, Inc.

3. Besterfield, D.H., 2008. Quality Control. 8th ed. United States of America: PearsonEducation, Inc.

4. Laudon, K.C. and Laudon, J.P, 2012. Management Information Systems. 12th globaled. United Kingdom: Pearson Education, Inc.

5.

Done for 2nd July

Documents

Transcript of Done for 2nd July