Group 3 Report Industrial Visit

8/16/2019 Group 3 Report Industrial Visit

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FACULTY OF INNOVATIVE DESIGN AND TECHNOLOGY

INDUSTRIAL VISIT REPORT

DMS 1053 (PRODUCTION MANAGEMENT)

GROUP 3

LECTURER NAME : PUAN LIANA BINTI YUSOF

STUDENT NAME MATRIC NO.

MUHAMMAD SYUKRY BIN KAMARUDIN 038977

FARIS SYAZWAN BIN IZANI 039514

MOHAMMAD HAZMAN BIN JALALUDDIN 039302


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PICTURE OF TEAM

Starting from left: Faris Syazwan,

Mohammad Hazman and Muhammad Syukry.


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TABLE OF CONTENTS

No. Contents Page

1 Introduction 3

2 Product Overview 53 Process Overview 6

4 Production Management 9

5 Question & Answers 10

6 Conclusion 12


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INTRODUCTION

We have visited 2 factories on 31 March 2016 until 2 April 2016 for our assignments which are :

1) NAME : SFCC CHEMICALS AND CASTINGS SDN.BHD

ADDRESS : NO. 13A, LORONG SANGGUL 1D, BANDAR PUTERI, 42100 KLANG, SELANGOR

DARUL EHSAN.

WEBSITE : www.sfcc.com.my

BACKGROUND : Has been develop first by Rajagopal and continued by his next generation.

Producing products based on casting processes and provide consultancy involved.

2)

NAME : BERYLS CHOCOLATE CONFECTIONARY SDN BHD

ADDRESS : NO. 2, JALAN RAYA 7/1, KAWASAN PERINDUSTRIAN SERI KEMBANGAN, 43300

SERI KEMBANGAN, SELANGOR DARUL EHSAN.

WEBSITE : www.berylschocolate.com

BACKGROUND : Beryl’s Chocolate and Confectionery Sdn Bhd was created with

one single aim – excellence. Since the company was established in 1995, our

focus has been on producing the very best chocolates for both the local and

global markets.

Their first factory was set up in 1995 in the small town of Desa Serdang located

at the southern zone of Kuala Lumpur. From humble beginnings, the company

started off by manufacturing consumer pack chocolates that were sold mainly

to duty free shops and supermarkets across the country. From there, they took

the first steps to establishing Beryl’s as a major regional chocolatier.

Shortly after that in 1998, they relocated and built their new factory in the Seri

Kembangan Industrial Area where they increased their production lines to

provide an even more diverse range of chocolate products to fulfil their

promise for high quality and delicious chocolates to their customers.

In 2008 and 2013, they opened up two more factories to keep up with thegrowing demands from their customers as well as further develop new treats

http://www.sfcc.com.my/http://www.berylschocolate.com/http://www.berylschocolate.com/http://www.sfcc.com.my/


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that their customers would love. The new factories helped expand their

capabilities to produce more than just consumer pack chocolates. Since then

they were able to produce chocolate for food service industries and move into

making cookies and other confectionery products.

Starting from their very first factory till today, Beryl’s Chocolate has since

become a well-loved consumer brand throughout the country and beyond.

Their products have been able to gain the recognition of discerning customers

from overseas and Beryl’s Chocolates can now be found in over 13 countries

around the world.


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PRODUCT OVERVIEW

SFCC CHEMICALS AND CASTINGS SDN.BHD

The factory produce : Boiler Spares And Packing

Foundry Chemical & Consumables

Ferrous & Non Ferrous Castings

Foundry Management & Consultancy

Spin Casting Machine And Furnace

Induction Furnaces Eletrotherm / Steadcast

Oven – Industrial Oven

Contitherm Burners – Gas And Oilfired

Heating Elements Mfg. And Supplies

Gravure Printing Rollers And Engraving

BERYLS CHOCOLATE CONFECTIONARY SDN.BHD

The factory produce :

DRAGEES Tiramisu Series

Jar Series

Box Series

Tin Series

BAR

Camior Series

Fruity & Nuts Series

No Sugar Added Series

ASSORTMENTS

Mini Box Series

Crunchy Series

Fruity Series

Pikko Series

GIFT

Souvenir Series

Gift Series

COOKIES

Butter Cookies

Coconut Roll Nougat


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PROCESS OVERVIEW


SAND CASTING

Sand casting, also known as sand molded casting, is a metal casting process characterized by using

sand as the mold material. The term "sand casting" can also refer to an object produced via the sand

casting process. Sand castings are produced in specialized factories called foundries. Over 70% of all

metal castings are produced via sand casting process.

Sand casting is relatively cheap and sufficiently refractory even for steel foundry use. In addition to

the sand, a suitable bonding agent (usually clay) is mixed or occurs with the sand. The mixture is

moistened, typically with water, but sometimes with other substances, to develop the strength and

plasticity of the clay and to make the aggregate suitable for molding. The sand is typically containedin a system of frames or mold boxes known as a flask. The mold cavities and gate system are created

by compacting the sand around models, or patterns, or carved directly into the sand.

The equipments needed in a sand casting process are:

1. Pattern

2.

Mould box

3. Moulding sand

4. Crucible

There are six steps in this process:

1. Place a pattern in sand to create a mold.

2. Incorporate the pattern and sand in a gating system.

3.

Remove the pattern.

4.

Fill the mold cavity with molten metal.

5. Allow the metal to cool.

6. Break away the sand mold and remove the casting.

INDUCTION MELTING PROCESS

An induction melting is an electrical furnace in which the heat is applied by induction heating of

metal.Induction furnace capacities range from less than one kilogram to one hundred tonnes

capacity and are used to melt iron and steel, sand,copper, aluminium and precious metals.

The advantage of the induction furnace is a clean, energy-efficient and well-controllable melting

process compared to most other means of metal melting. Most modern foundries use this type of

furnace, and now also more iron foundries are replacing cupolas with induction furnaces to melt cast

iron, as the former emit lots of dust and other pollutants.


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Since no arc or combustion is used, the temperature of the material is no higher than required to

melt it; this can prevent loss of valuable alloying elements.The one major drawback to induction

furnace usage in a foundry is the lack of refining capacity; charge materials must be clean of

oxidation products and of a known composition and some alloying elements may be lost due to

oxidation (and must be re-added to the melt).

INVESTMENT CASTING

Investment casting is an industrial process based on and also called lost-wax casting, one of the

oldest known metal-forming techniques. From 5,000 years ago, when beeswax formed the pattern,

to today’s high-technology waxes, refractory materials and specialist alloys, the castings allow the

production of components with accuracy, repeatability, versatility and integrity in a variety of metals

and high-performance alloys. The fragile wax patterns must withstand forces encountered during

the mold making. Much of the wax used in investment casting can be reclaimed and reused.Lost-

foam casting is a modern form of investment casting that eliminates certain steps in the process.

Investment casting requires the use of a metal die, wax, ceramic slurry, furnace, molten metal, and

any machines needed for sandblasting, cutting, or grinding. The process steps include the following:

1. Pattern creation - The wax patterns are typically injection molded into a metal die and are

formed as one piece. Cores may be used to form any internal features on the pattern. Several of

these patterns are attached to a central wax gating system (sprue, runners, and risers), to form a

tree-like assembly. The gating system forms the channels through which the molten metal will

flow to the mold cavity.

2.

Mold creation - This "pattern tree" is dipped into a slurry of fine ceramic particles, coated withmore coarse particles, and then dried to form a ceramic shell around the patterns and gating

system. This process is repeated until the shell is thick enough to withstand the molten metal it

will encounter. The shell is then placed into an oven and the wax is melted out leaving a hollow

ceramic shell that acts as a one-piece mold, hence the name "lost wax" casting.

3. Pouring - The mold is preheated in a furnace to approximately 1000°C (1832°F) and the molten

metal is poured from a ladle into the gating system of the mold, filling the mold cavity. Pouring is

typically achieved manually under the force of gravity, but other methods such as vacuum or

pressure are sometimes used.

4. Cooling - After the mold has been filled, the molten metal is allowed to cool and solidify into the

shape of the final casting. Cooling time depends on the thickness of the part, thickness of the

mold, and the material used.

5. Casting removal - After the molten metal has cooled, the mold can be broken and the casting

removed. The ceramic mold is typically broken using water jets, but several other methods exist.

Once removed, the parts are separated from the gating system by either sawing or cold breaking

(using liquid nitrogen).

6. Finishing - Often times, finishing operations such as grinding or sandblasting are used to smooth

the part at the gates. Heat treatment is also sometimes used to harden the final part.


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Starting from mix all the ingredients to make the chocolate-based.

Adding miscellaneous addition ingredients such as raisins, variety of nuts for delicious end

product that fulfill customers taste so that they happy and repeat order.

They do finishing well to improve performance of their end product. Hence, they packaging their products prettily before they distribute to the market.


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PRODUCTION MANAGEMENT


The factory adopt batch production which make product based on customers demand. Refer to themeaning of batch production that define as a form of manufacturing in which the job passes through

the functional departments in a lots or batches and each lot may have a different routing. So that

every product will be produce once customer placed the order. Then the next step they will proceed

until the end of the product and do the finishing. From that, the fact is shorter production is running

besides improve company’s achievement.

So in a nutshell, the types of production is batch production and the demand per year is based on

customers demand.


They were adopting both types of production which is batch and mass production, they make order

based on customers demand and does the process in a line production which follow every section

that has been set up earlier. Based on concept of mass production, products produced by following

the flow of work smoothly.

So in a nutshell, the types of production is batch and mass production and the demand per year is

usually in high quantities.


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QUESTIONS AND ANSWERS


General Questions

Q : Are the sand used have a binder?

A : Yes, it have a binder to make sure the sand have the texture that we want and we want to

maintain the shape.

Q : How the workers separate the spru and the product when the material are fully set?

A : They separate the spru and actual product by using the hammer. with the force, they will

break.

Q : Metal that they used to make the product, are they can be recycle too?

A : Yes, we also melted the metal that we got from spru of the last product we made.

Production Management Questions

Q:Your factory used batch production to produce your product.Did your factory face any difficulty

by adopting these types of production?

A: Yes, we are. The production equipment uses a lot of space. When it's idle, this space is not being

utilized to make money.

Q:What is your company demand per year?

A:We don’t have fixed demand per year.Our demand per year is based on customers demand.

Q:Based on what we have learned,disadvantages of batch production is required labor to move

items from one stage of the batch process to another,did your factory face this problem?

A:Yes,exactly.Labor is required for batch manufacturing.We usually lack of labor.


General Questions

Q : Where do this factory get the raw material with high quality from?

A : We got high quality raw material, cocoa from Ghana, where the quality were assured globally


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Q : What is your secret in attract customer to be regular and keep repeating order?

A : Our products for sure always maintain the quality and suits our customer’s taste. Plus, we also

practice Just In Time. We deliver the products on time in order to low the tardiness.

Q : You said that these product got higher demand from global market rather than local market, socan you tell us the specific place that high demand come from?

A : Yes, the fact that global market demand more is true, especially from Japan, Korea and Indonesia.

Production Management Questions

Q:What is your company demand per year?

A:Based on our sales statistic but usually we produce our product in high quantities per year.

Q:Your factory used mass production to produce your product.Did your factory face any difficulty

by adopting these types of production?

A: Yes,the problem is when the equipment breaks down,the entire process is halted.Worse, if

equipment malfunctions,then all products become defected until the problem is found.

Q:By adopting mass production as your factory types of production,what benefits for you by using

this types of production?

A: The probability of human error and variation is reduced, as tasks are predominantly carried out by

machinery. Also a reduction in labour costs, as well as an increased rate of production, enables our

company to produce a larger quantity of one product at a lower cost than using traditional, non-

linear methods.


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CONCLUSION

We have been able to see in front of our eyes on how these companies manage their companies by

using batch and mass production. Next , with this observation , we increasingly understanding on

how these types of production carried out by a factory.We also have got deeper explanation about

how they process their product by adopting these types of production.Last but not least,we have gotuseful on how the products going through the processes in order to produce high quality end

product.

Group 3 Report Industrial Visit

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