ABSTRACT

Students are required to undergo industrial training for 12 weeks as part of the

requirement to complete the 4 years course for the Bachelor of Engineering (Hons) Mechanical,

Universiti Teknologi MARA (UiTM). The attachment was held during the semester break of the

6th semester of the study. During the 12 weeks period of training, students will be supervised

and monitored by one supervisor. The Industrial Training was completed at Alps Electronics

SDN. BHD. Generally, ALPS is the manufacturer of electronic parts for most consumer cars and

some motocycles here in Malaysia. During the 12 weeks of training, the working environment

was successfully exposed in order to gain more experience and knowledge. A combination of

several tasks and projects were assigned which consists of technical and managerial aspects. The

scope of the assigned jobs will be discussed later throughout this Industrial Training report. All

of the related materials has been gathered and compiled and the report will focus on the projects

and processes that were involved during the engagement of the assigned tasks.

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1. Abstract 1

2. Introduction 2

3. Indutrial Environment 7

4. Industrial Experience 11

5. Industrial Project 18

6. Summary 21

7. Reference 22

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1)INTRODUCTION

1.1 COMPANY HISTORY

Alps Electric Co., Ltd.

The company first founded in 1948 as Kataoka Electric Co., Ltd in conjuction to the founder’s

name, Katsutaro Kataoka. The name was changed to Alps Electric Co. Ltd in December 1969.

Alps Electric currently possesses 25 companies all over the globe including Thailand,

India,Korea and China.

Alps Electric Companies

Alps Green Devices Co., Ltd.

Alps Electric(North America), Inc.

Cirque Corporation

Alps Electric Europe Gmbh

Alps Electric(Ireland)Limited

Alps Electric Czech, S.R.O.

Alps Electric Korea Co., Ltd.

Alps Electric(S) Pte. Ltd.

Alps Electric(Malaysia)Sdn. Bhd.

Alps Electric(Thailand) Co., Ltd.

Alps Electric(India) Pvt. Ltd.

Alps(China)Co., Ltd.

Alps Shanghai International Trading Co., Ltd.

Alps Communication Devices Technology(Shanghai)Co., Ltd.

Dalian Alps Electronics Co., Ltd.

Dandong Alps Electronics Co., Ltd.

Tianjin Alps Electronics Co., Ltd.

Ningbo Alps Elecronics Co., Ltd.

Wuxi Alps Electronics Co., Ltd.

Alps Electronics Hong Kong Ltd.

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Dongguan Alps Electronics Co., Ltd.

Alps Electronics Taiwan Co., Ltd.

Shenyang Xikang Alps Technologies Co., Ltd.

Kurikoma Electronics Co., Ltd.

1.2 STRUCTURE AND RESEARCH & DEVELOPMENT EXPENDITURE

Development of basic and advanced

technology takes place in Japan, though

designs of different product varieties

reflecting the needs of particular customers

and markets are developed regionally. Under

this format they promote global

standardization of technologies and products.

They also actively engage in joint research

with universities and research institutions around the world and development through

partnerships with other companies.

Technology

Alps Electric stands at the forefront of value creation, forever turning out original products to

react market needs and conditions. Fusion and advancement of technology is pivotal here as

mechatronics technologies amassed over the years are merged with process technologies

supporting functional device development and materials technologies used to develop and

identify the best materials.

IC design - Alps develops IP for modules and sensor circuits in an effort to meet the diverse

needs of manufacturers

Evaluation/Simulation – Alps uses data gethered over the years and software developed in-house

to create optimal products in short period of time

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Design/assembly – Alps has fully automated assembly and production of voice coil motors,

which are compact and yet drive even large diameter lenses

Optical design/molding – Alps delivers superior optical products using optical design and

molding technology to limit light interference and realize high transmittance

1.3 OBJECTIVES OF PRACTICAL TRAINING

Industrial training is one of the requirements for Bachelor of Engineering (Hons) Mechanical,

Universiti Teknologi MARA (UiTM). The objectives are:

i. To adapt readily to real-life working environment and practice right work attitude

Students should be able to adapt to actual working environment and learn on how to work in

a team.

ii. To apply knowledge learnt, gained new skills and be aware of current technologies

Students should be able to apply all the knowledge learnt into the industrial works as well as

gaining new skills during the industrial training.

iii. To identify the industrial problems and able to suggest possible solutions

Students are able to identify and analyse any problem that occurred during work and give any

possible suggestion in order to solve the problems.

iv. To facilitate students to potential employers

To take opportunities to show valuable characters to the employers and can contribute to the

progress of company in the future.

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1.4 SCOPE OF TRAINING

During the 12 weeks of industrial training, the appointed position was as a trainee under the

Engineering section in Nilai Engineering Department. The task was to improvise the work

envinroment for production throughout the training period. The actual working principle and

industrial practice was experienced as an extension to the theoretical knowledge acquired during

the study period.

1.2.1 Tooling Department

Learning about the role of a spare part engineer, it involves taking care of the spare parts and

program management. Any issues related about machine parts will be the spare part engineer’s

responsibility along with the related documentation. The documentation that is related to the

tooling engineer are Work Instruction Manual (WIM), Tool Order, Request Form (RF), Parts

Defect Report, and machine’s drawing.

MAJOR SCOPE OF TRAINING

1. PROCESS ENINEERING

2. DESIGN ENGINEERING

3. MECHANICAL ASSEMBLY ENGINEERING

4. ELECTRICAL ENGINEERING

5. PROGRAMMING ENGINEERING

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2) INDUSTRIAL ENVIRONMENT

2.1 TEAMWORK

Teamwork represents a cooperative and coordinated group of peoples working together

as a team with a common interest. In line with the vision of ALPS ELECTRICAL

(MALAYSIA)SDN BHD unit works to be the best-in-class in asset integrity and engineering.

The unit consisting of various teams collaborates together in ensuring effective completion of

work and project management. Thus, a good teamwork is very essential in this unit.

The team comprises of project management team, engineering team, construction team and

procurement team. Each and every one play a significant role in getting work done. Each team

has its own respective roles and responsibility and this leads to a well-formed organization. A

strong teamwork is displayed in the Engineering Services unit as everyone is running towards the

same objective and has a clear and precise goal. Since the unit manages project that involves

multidiscipline, all related engineering discipline member work as a team to ensure the projects

requirements are met.

Cooperation among the disciplines is vital in ensuring the work is carried out according to the

schedule. Department meetings and discussions are carried out to get updates for task that has

been completed and also for pending work. Opinions on improvement and strategy to overcome

challenges are proposed. Effective communication is the key to a successful teamwork. Ability

to communicate well allows a better understanding among the team. Strong leadership skills

displayed contribute to the effectiveness of teamwork when executing work. Under the guidance

and supervision of a great leader, work is completed in an efficient manner.

2.2 IMPLEMENTATION OF 5S

One of the methods of determining an organisations approach to its business is to evaluate its

workplace organisation capability & visual management standards.

5S engages employee through the use of Standards and Discipline. It is not just about

housekeeping, but concentrating on maintaining the standards & discipline to manage

envinronment product quality.

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Seiri

Sorting, keep the necessary in work area, dispose or keep in a distant storage area less frequently

used items, unneeded items are discarded. Seiri fights the habit to keep things because they may

be useful someday. Seiri helps to keep work area tidy, improves searching and fetching

efficiency, and generally clears much space. Seiri is also excellent way to gain valuable floor

space and eliminate old broken tools, obsolete jigs and fixtures, scrap and excess raw material.

Seiton

Systematic arrangement for the most efficient and effective retrieval. A good example of Seiton

is the tool panel. Effective Seiton can be achieved by painting floors to visualize the dirt,

outlining work areas and locations, shadow tool boards. For improving changeover time with

reduce machine downtime throught Total Productive Maintenance (TPM) it is necessary to have

tools at hand.

Seiso

Cleaning. After the first thorough cleaning when implementing 5S, daily follow-up cleaning is

necessary in order to sustain this improvement. Cleanliness is also helpful to notice damages on

equipment such as leaks, breakage and misalignment. These minor damages, if left unattended,

could lead to equipment failure and loss of production. Regular cleaning is a type of inspection.

Seiso is an important part of basic TPM; Total Productive Maintenance and Safety matter

through cleanliness is obvious.

Seiketsu

Standardizing. Once the first three S have been implemented, it should be set as a standard so to

keep these good practice work area. Without it, the situation will deteriorate right back to old

habits. Have an easy-to-follow standards and develop a structure to support it. Allow employees

to join the development of such standards.

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Shitsuke

Finally, to keep first 4 S alive, it is necessary to keep educating people maintaining standards. By

setting up a formal system; with display of results, follow-up, the now complete 5S get insured to

live, and be expanded beyond their initial limits, in an ongoing improvement way; the Kaizen

way.

2.3 OCCUPATIONAL SAFETY AND HEALTH

ALPS ELECTICAL as one of the most important company in Negeri Sembilan is very firm in

providing safe and healthy workplace for all employees working with its facilities and to

minimize the impact of its operations to the environment. Every ALPS group employee must

meticulously follow all the HSE requirements, measures, work rules and standard operating

procedures set out in manuals, handbooks and documents issued by ALPS as amended and

updated from time-to-time in all applicable laws and regulations.

ALPS ELECTRICAL Policy on Health, Safety and Environment

ALPS ELECTRICAL (MALAYSIA) Sdn. Bhd. is very committed to Health, Safety and

Environment (HSE) and shall take reasonable and practicable steps to eliminate, prevent and

minimize the risk of personal injury, occupational illnesses and damage to properties.

Besides that, they must implement effective risk control measures in all their activities; including

operations covering acquisition, exploration, development, production and abandonment which

will eliminate, prevent or reduce risks to a level as low as reasonably practicable. Moreover, part

of business philosophy and cultivate a desired HSE culture, they build an effective and resilient

HSE Management System as an integral part.

In addition, they provide competent workforce, adequate resources and organization in all their

activities in ensuring a safe environment at the workplace. Besides that, they promote continuous

improvement in HSE performance. Lastly, effective crisis management and emergency response

capabilities are also must be establish in all their operations.

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2.4 PERSONAL PROTECTIVE EQUIPMENT (PPE)

Personal protective equipment, commonly referred to as "PPE", is equipment worn to minimize

exposure to serious workplace injuries and illnesses. These injuries and illnesses may result from

workplace hazards. Hazards exist in every workplace in many different forms such as sharp

edges, falling objects, flying sparks, chemicals, noise and a myriad of other potentially

dangerous situations. Safety and Health Department takes an active role in providing personal

protective equipment for their employees and ensure that they are being used by them. PPE may

include items such as gloves, safety glasses and shoes, earplugs or muffs, hard hats, respirators,

or coveralls, vests and full body suits.

2.5 STOP WORK POLICY

Stop Work Policy of ALPS ELECTRICAL (MALAYSIA) Sdn. Bhd. grants every employee the

right to invoke a stop work order when there is an imminent and real threat which can physically

endanger them and others or cause adverse impact to the environment.

The management fully supports the decision of its employees in the diligent execution of this

policy. When there is doubt on whether work should continue, employees including contractor

staff, should promptly notify their immediate supervisor for assessment of the hazardous

condition.

Drug and Alcohol Policy

In accordance with Health, Safety and Environment Policy, ALPS ELECTRIC Sdn Bhd

recognizes that any drug and alcohol abuse will affect the employee’s work performance and can

be a threat to the company’s operations. It is the company’s policy that its employees and

workplaces are free from drug and alcohol abuses.

The company requires all its employees, contractors and others to strictly adhere to this

policy at all times. Joint venture partners of the company are expected to this policy at all times.

Joint venture partners of the company are expected to implement an effective drug and alcohol

programme, which is in line with the industry’s best practice.

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3) INDUSTRIAL EXPERIENCE

Throughout the training, the trainee was attached with the Nilai Engineering Department

(ENL), a department under Maintenanceor support Team in Nilai with advidor of Nilai

Engineering Department, Mr Yichijo from Japan. Working with this department, many

experience technical work and knowledge are gain during these 12 weeks. All the activity are

have the same objective which is to ensure all the machine equipment such as process, design,

mechanical, electrical and programming are in good condition and fully function well in order

keep the productivity of the line keep maintain to supply to the customer of the ALPS

ELECTRICAL (MALAYSIA) sdn bhd.

3.1 INTERNATIONAL STANDARDS

ISO 9001

ISO 9001 sets out the criteria for a quality management system and is the only standard in the

family that can be certified to. It can be used by any organization, large or small, regardless of its

field of activity. Alps was certified for its department’s procedure,work instruction procedure

and work instruction manual

ISO 14001

ISO 14001 sets out the criteria for an environmental management system and can be certified to.

It maps out a framework that Alps can follow to set up an effective environmental management

system.

ISO/TS 16949

ISO/TS 16949 defines the quality management system requirements for the design and

development, production and, when relevant, installation and service of automotive-related

products.

This industrial training provides an imperative platform for practicing effective

communication and developing communication skills. Having excellent communication skills

help to be successful in work and to deal with conflicts happening in workplace. Besides that, 11

effective communication skills are vital and significant in improving work and personal

relationships among the colleagues. Good communication skills reflect how well a person

expresses themselves. Both verbal and nonverbal communication skills are essential in leading to

a good and efficient communication.

All the activities that have been done are followed the working philosophy. There will be

specific notification to notify all the staff what the activity that need to done for that day. The

activity could be Preventive Maintenance, Reactive Maintenance or defect that have been noted

during the visual inspection by staff or noted by operation department for attends. There also an

activity where the task needs to be done at warehouse where to checking the ordered item that

has been arrived. There are several job engineer that can been obtain a experience such as:

Process Engineer

Design Engineer

Mechanical assembly Engineer

Electrical Engineer

Programming Engineer

Mechanical setting Engineer

3.2 PROCESS ENGINEER

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Before the department request about a machine, there are some process engineer needs to study

the process first. For example the request is about from the manual jig SDKZ machine to semi

auto SDKZ machine. So, in this case the process engineer needs to study the process, cycle time,

no of workstations and layout of the machine.

Figure 1: Wafer insert manual jig

Figure 2: Grease on the cam

Process engineer need to identified either they can improve the efficiency of the machine,

identified either can decrease the process needed by the machine or reduced the cycle time

needed by the machine.

3.3 DESIGN ENGINEER13

After the process engineer do their jobs, design engineer will take over the manufacturing

of the machine. Their jobs are to generate the 3d cad drawing by using Solidwork software.

Basically, design engineer need to know everything about the machine. It is because they have to

analyse the suitable part which is use in the machine. For example, for a SCCL machine in the

insert of spring, they need to use laser sensor. It is because the laser sensor only can detect the

present of spring.

Figure 3: Example of 3D CAD Drawing

Furthermore, there are two types of part to make of full machine which is standard part and

mechanical part. The difference between mechanical and standard part is mechanical part made

in Malaysia while standard part made in Japan. There are few examples of vendor in Malaysia

such as:

Mastool

Gms

Auto

Kanzen

There are few vendors from Japan:

Keyence (camera)

Omron (sensor)

Misumi (standard part)

SMC (vacuum,hose,cylinder)

3.4 MECHANICAL ASSEMBLY ENGINEER

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After design engineer generate the 3d cad and do their analysis, the part will arrived to be

assembled. In this case, assembly engineer will do their jobs. Engineer had done about their

analysis about mechanical parts, and find out that the quality of the vendors is different. The

best one is Mastools vendor. Assembly engineer would start their job by using a 3d drawing.

Figure 4: Assembly of the jig

The assembly of the machine is around 2 to 3 months. It depends on the mechanical and standard

part that was ordered. The part that was imported from the Japan takes time too long. While the

machine was assembled, there are some parts need to modified first. It is because to prevent the

jig from produce a NG product.

Figure 5: Machine

3.5 ELECTRICAL ENGINEER

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When the jig is about 90% to complete, the electrical engineer will take part in this job.

They will do some electrical wiring to the jig. In this scope, I have learned a lot of thing such as

how to use multimeter, fuse in the plug, wiring of 120v and 240 v of switch and connecting a

wiring from plc to the jig or machine.

Figure 6: Wiring the Plug

There are three types of wire in the plug which is live, neutral and earth. The colour of earth wire

is green which is in common colour. While for a live wire, the colour is sometimes black or

chocolate. For a neutral wire, the colour is almost blue in this country. Earth wire is on top of the

plug, while live is on the right where is the fuse located.

Figure 7: Wiring to the PLC

Electrical engineer will connect the wire from jig to the plc by read it from electrical

drawing. The drawing actually was imported from the Japan, so they know to connect it

properly.

3.6 PROGRAMMING ENGINEER

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After the electrical engineering have done about their jobs, the programming engineer

next will continue their works. in this case, the jig need to connected with plc. the type of

pragramming used is ladder diagram.

Figure 8: Ladder diagram

There are few types of plc in ladder diagram such as:

normally open (no)

normally closed (nc)

relay

timer

counter

Basically, if there have the old machine they just need to copy and paste the ladder diagram

program.

4) INDUSTRIAL PROJECTS

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4.1 Engineering Section

Objective

To learn the process of the machine

To design the part and assembly complete it

To assembly the jig properly so there have no more problem

To learn the electrical part

To learn how the program can make the machine move

To learn and implement the concept of KAIZEN for improving production quality

PIC : Mr. Chin Kar Long (Engineering section Manager)

4.2 SDKZ MACHINE ALLIGNMENT SETTING

Objective

To make sure the SDKZ machine is working properly

The produt is follow the Japan specifications

To reduce the cycle time of the machine

To increase the quantity of product

Problem

Production drops for new operators

Spring insert into the rotator

The quality of the grease is not follow the specification

Contact blade sometimes not insert correctly

The upper case and lower case sometimes cannot assembled correctly

Solution

Do a kaizen to the part of the machine

Do an analysis to the mold

4.2.1 PROJECT : GREASE ON CAM

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Figure 9 : Grease on Sdkz machine

At first, the quantity of the grease on the cam was 5. The specification of Japan is 8.

Pragramming engineer try to set the timing in the plc.

Design engineer do some kaizen to the cylinder part which is try to shorten the cylinder

holder.

We try to run the machine so many times and record the result.

Figure 10 : Grease on cam

Engineers identified that in 11 pallets that run, there are around 3 to 4 pallets that produce

not good quality of grease.

The reason of that quality is cause by the timing of the program. The cylinder that moves

down very fast are produce the quality that is not good enough.

4.2.2 PROJECT: SPRING INSERTION

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Figure 11 : Insert Spring sdkz machine

The spring need to insert to the rotator. Continued by inserted of ball to the rotator.

There have 6 cavity of rotator which is A, B ,C ,D ,E and F. the suitable rotator that can

used in semiauto SDKZ machine is cavity C only.

Engineer need to do kaizen so this kind of machine can use all of the cavity.

At first, the machine run 55 pallets of cavity C. the result shows only 4 pallets are

missing their spring.

Figure 12 : Spring in the Rotator

The latest result shown that the missing of the spring to the rotator is decrease.

5) SUMMARY

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Finishing the whole 3 months as Industrial Trainee is not as a piece of cake. During this

time, all trainees have to learn a real problem that happen in factory, learning new thing in very

different types of environment compare to lecture period. It is surely need the fully commitment

and hard work on the first day call as trainee until complete the training period. After I have done

my industrial training at ALPS ELECTRIC (MALAYSIA) SDN BHD, I can conclude that I have

learn a lot of things. There are so many thing that I can applied in the factory by using

knowledge I get from UiTM.

While follow the industrial training, I have been work as a process, design, mechanical

assembly, electrical, programming and mechanical setting engineer. I can know the flow how the

mcahine can produced from A to Z. This helps much to improve the communication skills and

understand the communication between different level of executive and staff here. Respects also

one of the values that learn here where student has to respect executive and staff here as well

Besides thought by fields work, student also trains on the soft skills which refer to the

communication as how they respect their family and lecturers. Other than that, working in a team

also a good value here as every day and each task or job given by supervisor was solved and

trouble shoot with technician team here. This creates a good relation among technician team with

student and helps in smoothing the working task.

6) REFERENCES21

Industrial training student logbook uitm

www.keyence

https://www.ia.omron.com/

http://www.misumi-europe.com/en/customer-service/request-catalog

Manager of Nilai Engineering, Mr zamri 0199199403

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