TABLE OF CONTENT PAGE

1. INTRODUCTION

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1.1 INTRODUCTION FOR INDUSTRIAL TRAINING 1.2 THE OBJECTIVE OF INDUSTRIAL TRAINING 1.3 THE SCOPE OF INDUSTRIAL TRAINING 1.4 SUMMARY FOR REPORT

2 2 3 3

2. THE BACKGROUND OF INDUSTRY

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2.1 THE PROFILE OF COMPANY 2.2 STRUCTURAL ORGANIZATION 2.3 MY DEPARTMENT 2.4 THE FLOW OF PROCESS IN THE INDUSTRY

5 6 7 7

3. OVERALL INFORMATION FOR TRAINING

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3.1 KITTING SYSTEM IN TOOL 3.2 GRINDING MACHINE 3.3 LASER CUT & TURRET PUNCH MACHINE(COMBO) 3.4 AUTO CYCLE LOADER ASR-48M 3.5 TURRET PUNCH MACHINE 3.6 SHEARING MATERIAL MACHINE 3.7 ELECTRONIC CARBIDE METAL IMPREGNATOR 3.8 FORKLIFT

20 23 25 28 29 29 30 32

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4. SPECIFIC INFORMATION FOR TRAINING

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4.1 THE IMPORTANCE OF LEARNING ALL THE MACHINES AND

EQUIPMENT
4.2 THE PROCEDURE OF WORK IN SYSTEMATIC AND EFFICIENT

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WAYS
4.3 PROBLEM-SOLVING METHOD ON THE PRODUCT OF FIRST

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BLANKING PROCESS
4.4 MAINTENANCE FOR MACHINE AND TOOL

5. CONCLUSION

5.1 CONCLUSION FOR INDUSTRIAL TRAINING PROGRAMME 5.2 PROBLEMS AND SUGGESTIONS

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LIST OF FIGURES

FIGURE PAGE 2.1 2.2 2.4.1 2.4.2

TITLE

WONG ENGINEERING CORPORATION STRUCTURE ALUMINIUM CHROMATING PROCESS LAYOUT ALKALINE ZINC PROCESS LAYOUT

6 7 18 19
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3.1(a) 3.1(b)

THE PART OF TOOL THE DIFFERENCE BETWEEN STANDARD TOOLING AND AIRBLOW TOOLING

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22 24 25 26 26 27 28 28 30 31 32 32 49

3.1(c) 3.2(a) 3.2(b) 3.3(a) 3.3(b) 3.3(c) 3.3(d) 3.4 3.6 3.7(a) 3.7(b) 4.3.3(a) 4.3.3(b)

TURRET DIAGRAM GRINDING MACHINE DULL RE PUNCH HEAD EML MACHINE EML MACHINE’S LAYOUT CNC PANEL TOOL CHANGE DOOR AUTO CYCLE LOADER ASR-48M SHEARING MATERIAL MACHINE ELECTRONIC CARBIDE METAL IMPREGNATOR GUN RECEPTACLE THE METAL PLATE WITH CONNECTOR THE WELDED POSITION FOR GUN RECEPTACLE AND DIE

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4.3.3(c)

THE REFERENCE OF SETTING POWER FOR METAL IMPREGNATOR 50

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CHAPTER 1 INTRODUCTION

1.1 INTRODUCTION FOR INDUSTRIAL TRAINING

As part of graduation requirements, all the undergraduates, the third year and forth year students, who take bachelor of mechanical engineering in UTM will undergo industrial training programme for a duration of ten weeks. This industrial training is a course for undergraduates that gives them an opportunity to expose themselves in the real career world so as to they will learn how to relate theoretical learning before and real practical in working’s environment. Besides that, in future, they will be having good preparation and understanding for their field of profession.
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1.2 THE OBJECTIVE OF INDUSTRIAL TRAINING

i.

Undergraduates have an opportunity to expose themselves in working’s environment of their field of profession respectively.

ii.

For obtaining working’s experience in the industry which is relating to their field of current study.

iii.

Using knowledge which is obtained from industrial training for their study after finishing training and continuing study at university afterwards.

iv.

Training them to be capable in communication and interaction between workers and superior.

v.

Training them to be able to prepare a technical report which is related to industrial training they do.

vi.
vii.

Cultivating them to work as a team. Learning to be professional behavior respectively.

1.3 THE SCOPE OF INDUSTRIAL TRAINING

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i. ii.

Observing the whole operation of this industry. Doing operation’s work that is involved in unit production by either using machine or tool.

iii. iv.

Work that involving installment and fabrication of tool. Visual inspection and quality control on the final product. Repairing any damaged tool if it still can use, or buying a new tool to replace it. Discussion and meeting with superior.

v. vi.

1.4 SUMMARY FOR REPORT

During the ten weeks of my industrial training, this industry allocated me as a beginner at the laser and turret punch sub-department which was involving primary process of the product and it belonged to manufacturing department. In the first day of the week, after visiting all the departments in this industry, I was given a task to learn about kitting system that I must know all the tools in those four cabinets. Indeed, I had to prepare a set of tools by according tooling list after I mastered all the tools.

After a week, I was given a manual book to learn how to operate those machines. There were a lot of machines at my sub-department; grinding machine, two turret punch machine, laser cut machine, one set of laser cut with turret punch combo machine, shearing material machine and auto cycle loader which was attached to that combo machine. After several weeks, I was
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starting to learn some new things. There were some technical skills I had to learn such as using electronic carbide metal impregnator, tooling maintenance and driving forklift’s skill.

Before I left this industry, I had to teach a few of new workers to learn all the knowledge I had been learned since I was worked here. I was started to teach them during ninth week and tenth week.

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CHAPTER 2 THE BACKGROUND OF INDUSTRY

2.1 THE PROFILE OF COMPANY

Figure 2.1 Wong Engineering

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Wong Engineering was established in October 1982. The company has since grown to become the leading manufacturer for high precision component parts in Malaysia. Located in the High Technology Park close to Penang in Northern Malaysia, Wong Engineering has ready access to tap into a pool of highly skilled professional talents in wide spectrum of industry sectors like Electrical & Electronic, Semi-conductor, Biotechnology, etc. This has help put Wong Engineering in a favorable position to offer its customer a competitive edge in manufacturing need.

Wong Engineering also provides product design, development and manufacturing services to its customers from wide spectrum of industries including the Oil & Gas, Aerospace, Telecommunication, Test Instrument, Automotive and Medical Devices sector.

Today Wong Engineering offers its customer a one-stop value added mechanical solution that encompasses the whole supply chain till the final assembly and delivers them with the right timing, pricing and quality.

2.2 STRUCTURAL ORGANIZATION

Wong Engineering Corporation Berhad

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Wong Engineering Industries Sdn.Bhd. (Precision Sheet Metal & Assembly)

Wong Engineering Electronics Sdn.Bhd. (Precision Metal Turned Parts)

WEC Marketing Sdn.Bhd. (Environmental & Heath Products)

Wong Exerion Precision Technology Sdn.Bhd. (Precision Technology in Welded Frames)

Figure 2.2 Corporate Structure

2.3 MY DEPARTMENT

WEC Marketing Sdn.Bhd. (Environmental & Heath Products)

There are many sub-departments in the manufacturing department. Each sub-department has different process respectively. The sub-departments are shearing material department, laser cut department, turret punch department, pending for filing department, sanding department, DET department, bending department, visual mechanical inspection department, insert nut department, spot-weld department, packing department, and visual inspection department, QQA final inspection
WEC Marketing Sdn.Bhd. (Environmental & SUBCON department, IQA dimension Marketing WEC Heath Products) Sdn.Bhd. department and finish good store (Environmental & Heath Products)

department. Furthermore, same as manufacturing department, production control department and development department that both departments also have their sub-departments.

After visiting all the sub-departments, I was sent to the turret punch department. My department is very important towards industry because major income came from my department. In addition, my department was primary process that is blanking process from a sheet of metal
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which went through the punching machine and eventually the product will be done after running the program. The product of first process will be carried out in other departments. For example, the product will be sanding in order to remove scraps, but usually it depends on customer’s request.

2.4 THE FLOW OF PROCESS IN THE INDUSTRY

FIRST PROCESS – BLANKING

A SHEET OF METAL

EML MACHINE (LASER CUT & TURR ET PUNCH COMBO )

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PRODUCT OF FIRST PROCESS

SECOND PROCESS – SANDING

PRODUCT OF FIRST PROCESS

SANDING

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FILING

PRODUCT OF SECOND PROCESS

THIRD PROCESS – DIE (DEEP IN EMBOSS)

PRODUCT OF SECOND PROCESS

WEC Marketing Sdn.Bhd. (Environmental & Heath Products)

EMBOSSING

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PRODUCT OF THIRD PROCESS

FORTH PROCESS – BENDING

PRODUCT OF THIRD PROCESS

BENDING

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PRODUCT OF FORTH PROCESS

FIFTH PROCESS – VISUAL MECHANICAL INSPECTION

PRODUCT OF FORTH PROCESS

VISUAL MECHANICAL INSPECTION

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PRODUCT OF FIFTH

SIXTH PROCESS – INSERT NUT

PRODUCT OF FIFTH PROCESS

INSERT NUT

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PRODUCT OF SIXTH PROCESS

SEVENTH PROCESS – SPOTWELD

PRODUCT OF SIXTH PROCESS

SPOTWELD

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PRODUCT OF SEVENTH PROCESS

EIGHTH PROCESS – PACKING

PRODUCT OF SEVENTH PROCESS

PACKING

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PRODUCT OF EIGHTH PROCESS

OTHER PROCESS – SUBCON (ZINC PLATE AND YELLOW CHROMATE)

BEFORE ETCHING

ETCHING

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ACID DIPPING

OVEN

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Figure 2.4.1 Aluminium Chromating Process Layout

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Figure 2.4.2 Alkaline Zinc Process Layout

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QUALITY CONTROL

IQA DIMENSION AND VISUAL INSPECTION

QQA FINAL INSPECTION

This department will check every process of bind off’s form that checking first part in a sheet metal before continuing the remaining parts. If the first part of a product is rejected, then the remaining part of a sheet metal that will stop cutting or punching the product out. It will keep repeating the first part until achieving the approved product.

This department will check the final products before it delivers for customer. If the final products are rejected, it will hold out for awhile either put in the store or send it back to production if the final products can be remade.

CHAPTER 3 OVERALL INFORMATION FOR TRAINING
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3.1 KITTING SYSTEM IN TOOL Kitting system is very vital work that needs someone to prepare tools by referring to tooling list for an operator and always keep all the tools in the cabinets in a good order. Those cabinets must always keep clean and tidy. This work is likely as an assistant operator. Firstly, I have to get knowledge about all varieties of tool and its function as well. The part of a tool will be shown in the figure 3.1(a).

DIE

STIPPER

PUNCH

HOLDER

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GUIDE

Figure 3.1(a) The part of tool In my department, there are two brands of tools. They are AMADA TOOL and WILSON TOOL. Both of them have their own significant design and function respectively.

AMADA TOOL is an airblow tooling which can ensure optimum tool life. It means it still maintains its component quality after 30,000 hits. In figure 3.1(a), it is shown the difference between standard tooling and airblow tooling.

Standard tooling after 30,000 hits

Airblow tooling after 30,000 hits

Figure 3.1(b) The difference between standard tooling and airblow tooling WILSON TOOL does not have airblow inside the tool. However, this tool is more convenient than AMADA TOOL, it can be set up easily. When changing any size of punch head and die, it is merely replacing punch head, die and stipper; guide and holder do not need to change. For example, the figure 3.1(a) is a set of WILSON TOOL. The people who is working
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at CAD room that their basic job is to create tooling list, production schedule and computer program. Moreover, ordering new tool is a part of job for CAD room’s people. Therefore, it is only necessary to buy punch head, die and stipper if they want to order any particular size of tool but it depends on customer’s drawing.

Every die has their tolerances. For instance, tolerance = ± 0.25 mm, tolerance = ± 0.35 mm, tolerance = ± 0.65 mm. The size of tolerance for a die will be selected whom base on thickness of a sheet metal and type of material. There are five types of punches which are round(RO or RD), rectangle(RE), square(SQ), oblong(OB) and special tools(SP). Special tools are tools that the tools have any type of pattern and shape but excluding tools which are mentioned before. Every special tool has their SO number respectively. For example, one of special tools is countersunk tool and its SO number is SO: 643899-10. Furthermore, special tools are including marking tool, banana tool, slotting tool, cluster tool, semi corner radius tool, emboss tool, SE(down) tool, T-tool Fermi-T shape tooling, micro joint tool and so forth.

Besides that, there are different types of station for tooling. The tooling classifies becoming bigger and heavier in the arrangement below. More details has been shown in figure 3.1(c).

A station < B station < C station < E station < G station < H station
SIZE, WEIGHT, COMPLEXITY OF TOOL ARE INCREASING

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A STATION

B STATION

C STATION

E STATION G STATION H STATION

Figure 3.1(c) Turret Diagram Above all, after understanding all the details in tooling, set up tool and tooling preparation will be no problem. This is all about kitting system that it seems very simple work but actually it needs knowledge and technical skills to master it. Maintenance on tooling also regards as a part of kitting system that it will be discussing in chapter 4.4.

3.2 GRINDING MACHINE

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Grinding machine is a very important machine that it can be functioned as sharpener for turret punch tooling. It can grind any punch head in the length between 0 mm and 0.99 mm. The punch head which has wore out already that needs to be ground since it have been using regularly. The example of dull punch head has been shown in figure 3.2(b). The machine is an automatic grinding machine and its model is TOGU-IILEXP (AMADA). The grinding machine has been shown in figure 3.2(a).

Figure 3.2(a) Grinding Machine

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The top of punch head was dull. It is obviously the edge of RE punch head was corner-rounded a bit.

Figure 3.2(b) Dull RE Punch Head 3.3 LASER CUT AND TURRET PUNCH MACHINE (COMBO)

Figure 3.3(a) EML Machine This machine is the most expensive machine in this industry. The EML machine has been shown in figure 3.3(a). It costs eight-figure approximately. It needs nitrogen gas, oxygen gas and laser gas for laser cutting. The EML machine’s lay out has been shown in figure 3.3(b).

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Figure 3.3(b) EML Machine’s Lay Out

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Figure 3.3(c) CNC Panel

Toolin g

Figure 3.3(d) Tool Change Door In figure 3.3(c), it is CNC panel that it uses for computer program. In figure 3.3(d), it is a tool change door that it uses for changing tools.

All the gaseous tanks are ordered from MOX companies that they are very costly. Thus, the EML machine is the highest expenses in this industry. Apart from the machine is very expensive, its performance is undoubtedly efficient and accurate. Despite of unusual shapes or patterns or degrees that it seems very difficult to cut the product out, a high quality product will
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be produced that is matching exactly with the drawing of product and all the dimensions are precise and standard. By comparing to a normal turret punch machine, the advantages of EML machine are reducing the possibility of overloading and overlapping tooling in the machine. The overloading and overlapping cases will be discussed in chapter 4.1.

In general, this combo machine can use for punching and cutting out material.

3.4 AUTO CYCLE LOADER ASR-48M It also called as material cycle changer. It is a machine that is a part of the EML machine but it has its own CNC panel. It means it cannot be controlled by EML’s CNC panel which only connects to it.

The machine has been shown in figure 3.4. The advantage of this machine is able to pick the sheet metal into the EML machine consecutively. Instead of some material is being carried by workers that the material is heavy and impossible to move, the machine can solve this problem. Especially, cold rolled steel(CRS), copper, hot rolled steel(HRS) and electro galvanized(EG) and galvanized steel zero regular spangle(GI), these are heavy materials.

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Figure 3.4 Auto Cycle Loader ASR-48M

3.5 TURRET PUNCH MACHINE There are two turret punch machines in this industry. Both of them seem to be similar in function but they are different in models which their models are EM 2510NT and VIPROS 2510 KING. They can only punch material but cannot cut material. However, these machines can make the product easily to remove without cutting but punching around the shape out of the sheet metal and the edge of the product is merely tiny joins between product and frame of sheet metal. These joins can be broken by using screwdriver with flat head.

3.6 SHEARING MATERIAL MACHINE Shearing material machine is a machine that is used for cutting material which is the rest of sheet metal after product has been taken out in order to separate the frame of product and the
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remaining material which is still uncut. The remaining material can be used when it is necessary. Sometimes some materials need to cut out first before using at turret machines, a sheet metal may be cutting to several pieces. This is a precaution for avoiding scratches or bending on the product. If the product needs to be punching like ‘bee nest’ in shape and the whole sheet metal is only able to produce six products, it will occur bending on the surface. There is no problem if a sheet metal is cutting to six pieces and each piece for one product.

In the case of scratches on the product, it is due to the heavy material and the scraps is stuck inside the dies which is inside the machine will rub with the surface of sheet metal below. There is no problem if a sheet metal is light and thin. The shearing material machine has been shown in figure 3.6.

Figure 3.6 Shearing Material Machine

3.7 ELECTRONIC CARBIDE METAL IMPREGNATOR
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Electronic carbide metal impregnator is a device that is used in order to prevent any scrap jump on the surface of sheet metal when the machine is running. The gun receptacle has to plug in the electric discharge selector, then adjusting volt and it is ready to use. More details will be discussed in the chapter 4.3.

Figure 3.7(a) Electronic Discharge Selector

Figure 3.7(b) Gun Receptacle
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3.8 FORKLIFT As we all know, forklift is really useful for carrying anything that human cannot carry it. In this industry, there have six forklifts which are automatic gear. It is easier to drive an automatic forklift than manual forklift.

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CHAPTER 4 SPECIFIC INFORMATION FOR TRAINING

4.1 THE IMPORTANCE OF LEARNING ALL THE MACHINES AND EQUIPMENT

It is quite headache if you cannot find the suitable station of a tool for machine, so there are some equipment you can use to change any station of tool to suitable station of tool. The equipment are adapters. For example, there is only 3x1 mm, RE, A station of tool can use adapter to become B station of tool. There are two types of adapters which are A station to B station and B station to C station. Both of two types of adapters can stack together as a result A station to C station.

It is not quite reliable by using program from CAD room and transferring it through diskette to CNC panel. In the case of overlapping, it means the machine is having two or more tool which is same size, shape and station. For example, there are two tools which are 15x3 mm, RE, B station in the machine. Consequently, it will cause overloading tool in the machine that means too much tools in the machine and becomes burden to the machine. We can settle these problems by placing one tool in the location of auto index station. Auto index station can rotate any tool to any degree. In contrast, sometimes programmer sets one tool at 0 degree and another tool at 90 degree that both of tools are same, but putting one tool in the auto index station is more preferable. After placing tool in the auto index station, we must edit the program by changing the station number.

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It needs to edit the program if all the pallets of sheet metal are empty, because we can reuse the remaining material which is still uncut. Therefore, without knowledge how to edit the program you will affect the schedule of running product.

4.2 THE PROCEDURE OF WORK IN SYSTEMATIC AND EFFICIENT WAYS

In this industry, all the workers must do their tasks in a great order. Each step for procedure of work must follow step by step instruction in order to prevent any accident happens and any missing step of work that will influence the final product. In fact, there is a daily schedule we must follow to ensure how many products will be produced within days, months or even years. There are few procedures of work I would like to discuss.

4.2.1 THE EML MACHINE FLOW

START UP EML MACHINE FLOW:

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39

40

41

OPERATING EML MACHINE FLOW:

42

43

44

45

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4.2.2 EML MACHINE SCHEDULE FLOW FOR TURRET PUNCH DEPARTMENT My department is only involving blanking process which is primary process. After finishing the product of first process, it will transfer to other department to continue the next
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process. However, each department has their own schedule that they must obey it. If any department cannot finish their product on time, they will have to work on weekends or overtime (OT) during weekdays. The schedule flow has been shown in the following below.

48

49

50

51

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4.3 PROBLEM-SOLVING METHOD ON THE PRODUCT OF FIRST BLANKING PROCESS

Sometimes the products get rejected are not because of the workers do not follow the step-by-step instruction, in actual fact, they are ignoring some trivial issues without carefully. More details will be discussed in the following below.

4.3.1 DIMENSION PROBLEM

If the thickness of material is greater than 1.6 mm (such as 1.8 mm, 2.0 mm, 2.3 mm, 2.4 mm or 2.5 mm), you have to increase the size of die but maintain the size of punch. For example, if the thickness of aluminium is 2.0 mm and RO 3.3 mm of tool is required, the die of tool should change to 3.5 mm by taking other die of the tool. The increasing of size of die can increase the tolerance for overcoming that material with larger thickness. This can prevent the punch head of tool is damaged by the material and the product as well.

4.3.2 MATERIAL PROBLEM
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Normally, the problem about material is because of the origin of sheet metal. There are two cases that have happened about problem of the material. The first case is the sheet metal has occurred scratches that the surface of sheet metal may be caused by the metal manufacturer. The second case is the mistake of given information for the thickness of material. For example, the sheet metal we have ordered is 1.6 mm Aluminium, but the metal manufacturer gave us 1.8 mm Aluminium. We can solve the problem by ordering the sheet metal with laminated plastic. However, the laminated sheet metal is not suitable for EML machine, because it will cause burning on the sheet metal due to the laser cut. So it is only used for turret punch machines; VIPROS 2510 KING and EM 2510NT.

4.3.3 TOOL PROBLEM

There are several cases that the machine is out of order because of the problem of tool. The first case is the die has stuck with scraps as a result the die was broke. The second case is the punch head has stuck in the die and the material in the middle of them. It may be caused by the tool which was dull and the tolerance of die was not suitable or too small in size. The third case is the operator is reckless when he is setting up tool in the machine, he put the die in the wrong location of station. Consequently, the tool was damaged and machine will stop working because of these problems. However, these problems can be solved by using metal impregnator to improve the performance of die. The method of using metal impregnator has been shown in figure 4.3.3(a), (b) and (c).

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Figure 4.3.3(a) The Metal Plate With Connector

Figure 4.3.3(b) The Welded Position For Gun Receptacle And Die

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Figure 4.3.3(c) The Reference Of Setting Power For Metal Impregnator

Normally, the power of 50 will be preferable. After using metal impregnator on the die, the scraps will neither jump on the surface of sheet metal nor stick inside the die. 4.4 MAINTENANCE FOR MACHINE AND TOOL

The maintenance for machine and tool are extremely important work for us in order to keep them in good performance all the time. The EML needs to fill up lubricants and oils if machine’s tanks are empty or low level. Besides, the air dryer needs to clean every month if not the machine will stop working. In addition, the service of tool is necessary every week. The punch head of tools have to grind if they are dull or not sharpen. Sometimes we use lime with blue oil to clean at the side of punch head in order to make it smooth and flat.
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CHAPTER 5 CONCLUSION

5.1 CONCLUSION FOR INDUSTRIAL TRAINING PROGRAMME In conclusion, I would like to conclude that I have learned a lot of knowledge which I cannot obtain in the books or references. Even though it is only ten weeks of training, the
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experience in the industry during ten weeks is valuable for me. I have learned to be responsible for my position and be punctual on work. It can be said that “Patience is bitter, but its fruit is sweet.”

5.2 PROBLEMS AND SUGGESTIONS

There are some problems I have to face with them. The distance between industry and my house is 22 km. The usage of fuel is costly towards me. But fortunately the industry has given me allowances of RM 500 for every month. I was living in my house during ten weeks. Therefore, I still have earned money a bit. It is helpful if our faculty is giving some allowance for those trainees who have to rent house themselves.

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