KULLIYYAH OF ENGINEERING

INTERNATIONAL ISLAMIC UNIVERSITY MALAYSIA

ENGINEERING INDUSTRIAL TRAINING

AT
PERODUA MANUFACTURING SDN. BHD.
8 JUNE 2015 - 28 AUGUST 2015

NUR AIN MASTURA BINTI BURHANUDIN

1128366
MECHANICAL-AUTOMOTIVE ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING
2015

COMPANY VERIFICATION STATEMENT AND COMPANY STAMP

I hereby declare that Nur Ain Mastura binti Burhanudin and 1128366, student of department
Mechanical Engineering, International Islamic University Malaysia (IIUM) has successfully
completed her Engineering Industrial Training from 8 June 2015 to 28 August 2015 at Perodua
Manufacturing Sdn. Bhd. This report is prepared by the above-mentioned student as a partial
fulfillment of this training. All information given in this report is true and does not contain any
confidential information or classified data that might in a way or another abuse the companys
policies.

MR. MOHD FAHMI BIN MD. ISA

MANAGER
DEPARTMENT OF QUALITY CONTROL
PERODUA MANUFACTURING SDN. BHD.

ACKNOWLEDGEMENT

In the name of Allah, the Most Compassionate, the Most Merciful

Alhamdulillah, with blessing from Allah S.W.T, this practical training has been
completed successfully according to the targeted period. I would like to thank International
Islamic University Malaysia and Perodua Manufacturing Sdn. Bhd. for giving me an opportunity
to fulfill my Engineering Industrial Training as part of Bachelor of Engineering (MechanicalAutomotive) (Honours) requirement.

I would like to express my greatest gratitude to my Supervisor, Mr. Mohd Fahmi bin Md.
Isa for his continuous technical and moral support throughout the Engineering Industrial
Training. Special thanks to all staff in Quality Control Department especially in Quality
Engineering Section; Mr. Suhaimi, Mr. Asmawi, Mr. Mior Azmi, Mr. Mazarul Fazlin, Mr.
Khairul Anuar Mazlan, Mr. Mohd Nazari, for guiding me when I have difficulties during this
training. This training would be less meaningful without their guidance.

Finally yet importantly, my appreciation goes to my parents and my family who have
been giving me courage and advice in completing this training.

TABLE OF CONTENT

TITLE

PAGE

Company verification statement and company stamp

Acknowledgement
Table of Contents
List of Tables
List of Figures

ii
iii
iv
v

CHAPTER ONE
General Information
1.1 Background of the companies
1.2 Company Organization Chart
1.3 Principal activity of company
1.4 Description of department/unit attached with
CHAPTER TWO
Summaries of duties
CHAPTER THREE
Working Experiences
3.1 Projects carried out
3.2 Supervisory works
3.3 Problems encountered
3.4 Problems solving process, approach

CHAPTER FOUR
Conclusion

CHAPTER FIVE
5.1 References
5.2 Appendices

CHAPTER THREE
Working Experiences

PROJECT 1:

3.1 Projects carried out

Solving problem of parts in Quality Engineering Section in Quality Control Department.

3.2 Supervisory works

Checking the parts with the defect stated in TeSIAR (Troubleshooting and Information Action
Report) form. I have been assigned to assist the Engineer, Mr. Khairul Anuar Mazlan to solve the
problem.

Part Name: Tube FR Brake No.4

Part No: 47314-BZ400
Quantity: 1 Case
Detected by: Installation Process (Assembly Line)
Method and Finding: Visual Comparison (NG - Not Good)
Rank of defect: White cross
Sorting Activities: Can Sorting
Total Check Parts: 220 pieces;
Brake No.4

70 pieces from A2 Assembly Line, 150 pieces from Logistic Section

Total NG Parts: 11 pieces;
3 pieces from A2 Assembly Line, 8 pieces from Logistic Section

Figure 1 : Tube FR

Figure 1 TeSIAR Form

3.3 Problems encountered

Tube FR Brake No.4 cant insert with the Hose Flexible Hole.
Suspected Cause: Tube Brake Bending Out

Figure 2 Tube Brake Bending Out

3.4 Problems solving process, approach

1. Find the drawing of the parts in computer at Quality Engineering (QE) office and print it.
The purpose is we need to verify the NG part follows the dimension of its drawing.

Figure 3 Brake Tube Drawing

2. See how the team member / man power install the parts at Assembly Line.

Figure 4 Installation Process

3. Verification of parts
a) Compare the NG parts with OK parts by using measurements, visual, swapping or
trial.

Figure 5 Comparison of parts

b) Compare the dimension of parts with the actual drawing.

c) Check the accuracy of parts by using the molding tools called Checking Fixture (CF).
The CF tools is brought by the vendor (Company Name: IQM) into the Perodua
factory. The parts do not have any defect after check with the CF.

Figure 6 Checking Fixture

d) Currently waiting the report from vendor either the parts are valid or invalid. If the
part is valid, the vendor will get the penalty for causing the problem to Perodua. The
penalty is the vendor have to pay RM500 for 1 minute downtime. In this problem, the
total downtime is 3.6 minutes. But, the final conclusion is still in progress. We need to
discuss with the vendor and VED (Vendor Entertain Department).

PROJECT 2:
3.1 Projects carried out
Solving the abnormal noise problem of LH I.P (Instrument Panel) in the new production car.

3.2 Supervisory works

Checking the car that has abnormal noise problem in left hand side of instrument panel. I have
been assigned to assist the Engineer, Mr. Khairul Anuar Mazlan to solve the problem.

3.3 Problems encountered

Abnormal noise produced near the airbag section at the left hand side of instrument panel. We do
not know the root cause for this problem.

Model: Myvi
Chassis No: 130077
Color: P11 (Purple)

3.4 Problems solving process, approach

I have been followed Mr. Khairul Anuar Mazlan to solve the problem. The car need to be tested
in test track in Dynamic Inspection (DI). DI is the second last process before the production car
is send to Station 14 (final process) for adding the accessories. Below is the layout of DI.

Figure 10: Dynamic Inspection Layout

Dynamic Inspection consist of:

1. High Speed Test
2. Hill Test
3. Wave Test
4. Normal / Rough Road
5. No.8 Course

In this problem, we went into High Speed Test and Normal / Rough Road to check the
abnormal noise. The noise is heard. We are detected the noise by using sense of hearing. Hence,
the centre interference is detached its parts one by one to check the noise.

The engineer has detached the air cond register part, as shown in the picture below.

Figure 7 Air cond register part detached

He drove the car on the rough road for second time without the air cond register part. As
a result, there is no abnormal noise heard. He later attached again the part into its position, and
drove the car for the third time. Luckily, there is no abnormal noise after the part is being
attached again. He repeated to drive the car on the rough road for several times to confirm there
is no abnormal noise occurred again. He also asked me to reconfirm there is no abnormal noise.
Alhamdulillah, the problem is solved.