CHAPTER 1

INTRODUCTION

1.1 OVERVIEW

Industrial Training (INTRA) is one of the requirements for all Kolej

Kemahiran Tinggi MARA & Institut Kemahiran MARA students of Diploma/Sijil
Programmers. The industrial training supplements the student’s academic education
in engineering courses by exposing them to practical experience in an actual working
environment; opening avenues for them to develop their skills and capabilities.

1.2 OBJECTIVES

Students will able to apply the skills that they have gained throughout their
academic years. In addition, they can enhance their knowledge and abilities at the
companies that they attached to.

This internship is also a shared social obligation for both KKTM and the
practical companies involved. KKTM practical students will assist the companies in
handling any related jobs and it also enables KKTM to identify industries’ current
needs, hence improving any weaknesses discovered. Therefore, The KKTM will be
able to strengthen its curriculum and produce graduates who are market ready.

1
1.3 INTRA DETAILS

COMPANY NAME SONY EMCS (M) SDN BHD

COMPANY ADDRES Lot 5, Jalan Kemajuan,
Bangi Industrial Estate,
43650 Bandar Baru Bangi,
Selangor Darul Ehsan.
CONTACT NO.
OFFICE: 03 - 8925 7587
FAX: 03 - 59252649
DEPARTMENT Television Quality Reassurance (TV QR)
ATTACHED
COMPANY Mrs. Mazlinda Binti Abdul Majid
SUPERVISOR
DESIGNATION Senior Engineer

Table 1.0: INTRA Detail

1.4 POSITION GIVEN

The student was positioned at the TVQR department. In this department, the
student was located under Product Safety (PS) group which conduct five type of
testing like Realibility Incident Preventive Rule (RIPR), Leakage Current, Power
Consumption, Fool Proof, and Smell Test & Outgas. As a trainee, student was put
under smell test & outgas group.

1.5 DEPARTMENT ATTACHED

The student must report their progress to designated Company Supervisor.

For this purpose, the student must report to Mrs. Mazlinda Binti Abdul Majid. For
KKTM Supervisor, the student must report to Sir Shahril.

1.6 TASKS

The major task that the student has to do in this department is to perform
Smell Test and Outgas testing. Other than that, the student need to borrow and return
TV set from logistic to do testing and troubleshooting the problem, inspection
dissemble, assemble, 5S+2S, and kaizen in the TVQR department.

2
 CHAPTER 2

GENERAL PRESENTATION OF THE COMPANY

2.1 COMPANY PROFILE

Sony Corporation is a Japanese multinational corporation and one of the

world's largest media conglomerates with revenue of $68.39 billion (as of 2006)
based in Minato, Tokyo. Sony is one of the leading manufacturers of electronics,
video, communications, video games, and information technology products for the
consumer and professional markets. Sony Corporation is an operating-holding
company. It is the electronics business unit and the parent company of the Sony
Group, which is engaged in business through its 5 operating segments are
electronics, games, entertainment (motion pictures and music), financial services and
other. These make Sony one of the most comprehensive entertainment companies in
the world. Sony's principal business operations include Sony Corporation (Sony
Electronics in the U.S.), Sony Pictures Entertainment, Sony Computer
Entertainment, Sony BMG Music Entertainment and Sony Financial Holdings. Sony
is also among the Worldwide Top 20 Semiconductor Sales Leaders. Its slogan is
“Sony.Like.No.Other.”

2.2 HISTORY AND VISION

The name 'Sony' was created by combining two words. One was the Latin
word, 'sonus,' which is the root word for 'sound' and 'sonic.' The other was 'sunny,'
meaning little son. The name symbolizes Sony's spirit and motivation to stay
committed to its customers as well as to enhance its reputation in taking its
innovations into the future of digital technology.

Sony has helped developed discerning Malaysians who have come to expect
quality, integrity and reliability in audio/visual equipment. Sony's cutting-edge
technology brings sights and sounds, expectations and experiences into the home as
well as the office. In line with Malaysia's VISION 2020, Sony’s future will focus on
the dynamic digital era with even sharper cutting-edge technology. The future is
filled with exciting promises for continuous and rapid growth.

3
Founded by Masaru Ibuka and Akio Morita in 1958, the Sony Corporation has come
a long way since its first transistor radios. Being innovative thinkers, the founders
realized a need for a global brand with mass appeal. Hence, as the company grew, it
was simply logical to establish production facilities in their respective regions.
Since its inception, very few have been able to match Sony's track record for
invention and innovation. These include the first Trinitron colour television (1968),
the colour video-cassette (1971), the renowned Walkman (1979), the world's first CD
player (1982), the 3.5-inch floppy disk (1989) and many others.

Illustration 2.0: Masaru Ibuka Illustration 2.1: Akio Morita

The origin of Sony goes way back to May 1946. Back then, its original name
was Tokyo Tsushin Kogyo K.K. (Tokyo Telecommunications Engineering
Corporation). The founders, Masaru Ibuka and Akio Morita, wanted a name that can
be easily remembered by the world. This was essential to achieve success in the
global market.

Their vision was for Sony to become an endearing household name across the
globe. With this in mind, Morita came up with the term 'global localization' in 1988.
He said, "In this day and age, many companies are pursuing globalizations, but
instead, we should move ahead with a policy of global localization, meaning that we
set down roots and truly become an integrated member of the local community."
Sony's mission is to establish an 'ideal' factory that puts emphasis on the spirit
of freedom and open-mindedness and also a place where designers and engineers can
work out their creative and technological skills to the highest potential.

4
 LOGO AND LEGAL STATUS

2.3 SONY CORPORATION

Sony's assets are neither its buildings, nor its land. Sony's greatest asset is the
image of the four letters: S-O-N-Y. Just as in the past, for Sony to succeed in the
future, it must raise its brand image and create innovative products. Innovative ideas
are the most important aspect of creating Sony products. Technology supports those
ideas afterwards, but the ideas must come first. To create products that alter the
industry, we must have the ability to foresee future trends and the unlimited
imagination to dream up new products. Most important of all, we must not only
think of today, instead we must think three to five years from now. We must be very
perceptive to what our customers want. We want our customers to say, "I am glad I
purchased a Sony product," so we must create products that pull at their
heartstrings.

Illustration 2.2: Sony Group Companies in Malaysia

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 Type of Company Multinational Company
Lot 5, Jalan Kemajuan,
Bangi Industrial Estate,
Location 43650 Bandar Baru Bangi,
Selangor.
RM 972 million (USD 256
Employee Investment
million)
• Color Television
• LCD Television
• Projection Television
• Tuner
• Deflection Yoke
Products Manufactured • Fly Back Transformer
• Digital Video Decoder (DVD)

Table 2.0: Company Specification

In Malaysia, there are four branches of Sony factory, which is Sony

Electronics (M) Sdn Bhd, Sony Technology Malaysia Sdn Bhd, Sony Logistics (M)
Sdn Bhd and Sony EMCS (Malaysia) Sdn Bhd. Sony Bangi is one of the factory
th
which produced Sony’s branded Television. It was built in 7 October 1987, the first
st
operation and production of this factory begin from 1 April 1988. In earlier this
factory is known as SONY TV/Video (M) Sdn. Bhd. because of its only produces
TV and Video. However when the SONY Video building was completely launched,
the name was changed to SONY TV Industries. Year after year revolution this
industries changed to SONY EMCS where divided to KL Tech and Penang Tech.

Sony TV not only producing items for local market, in fact almost 90% of
SMT (TV) production is to export for foreign markets while the excess for domestic
market. This factory introduces the TV from smallest size 14 inches to the largest 61
inches. WEGA is the most popular model nowadays which used flat screen. Besides
that, COMBO TV is also produced where this model is the combination of TV and
Video. The major target markets are Japan, Australia and West Asia.

6
2.4 MAIN PRODUCT

1951-1955 The Dawn of a Technological Revolution

In 1955, Sony developed the world's first transistor radio. Small and extremely
functional, the transistors heralded a new technological era with its potential.

1956-1960 The World is Our Market

In 1958, the company officially changed its name to Sony Corporation and this
marked a new beginning for the company. As global markets began to grow,
products stamped with the Sony trademark were widely gaining acceptance and
popularity. During this period, revolutionary technologies and the world's first
transistor televisions were developed, paving the way to an electronic revolution and
the video tape recorder.

1961-1965 Sony, the Guinea Pig

During this period, Sony was often referred to as a corporate guinea pig, an
experimental animal likely to be gobbled by the big companies that follow behind.
Despite this risk, Sony continued to develop new products using transistor
technology and led the way to capture the attention of the world.

1966-1970 Just Another Company?

Sony entered a difficult period. Competitors from around the world were nipping at
Sony's heels. Sony had just spent a huge amount of time and money developing the
colour television, the video tape recorder, and the SOBAX calculator. Despite the
economic downturn in Europe and many daunting challenges, Sony finally created a
new colour television, dubbed the Trinitron.

1971-1975 Manufacturing Closer To The Market

As big corporations around the world began relocating manufacturing facilities to
places like Taiwan and Southeast Asia, Sony promptly began setting up a series of
overseas manufacturing facilities closer to the consumer market. This was a
significant first step towards truly becoming a world enterprise.

1976-1980 The Age of Video

After 20 years of accumulated research and development of video technology, Sony
developed the Betamax VCR - a product seen to create new lifestyles.
7
1981-1985 Birth of the Walkman Generation
Entering the 80s, Sony forcefully promoted the development of the CD and 8mm
video. The introduction of Walkman personal stereos created a huge sensation in the
80s - taking music outdoors anywhere, anytime. It immediately became a lifestyle of
young people around the world.

1986-1990 Pioneers in the AV Industry

Sony was gaining momentum and self-sufficiency, resulting in new product
development across all AV fields. Establishing itself in worldwide markets, Sony
was fact becoming one of the world's leaders in AV products.

1991-1996 Towards Multimedia and Entertainment

The digital wave was gathering momentum, making inroads in many areas of life
around the world. Sony's operations already encompassed hardware and software,
covering audio, video, communications and computers. Sony had already
strengthened its position for the 21st century but was now faced with a new
challenge - the digital age and making a fresh start towards realizing the dream of the
digital age.

2.5 SONY KL TEC

SONY TECHNOLOGY MALAYSIA (STM) OPENING DATE

APRIL 1988

(STM) KL TEC MERGE WITH (STM) PENANG TEC

1 APRIL 2004

SONY NEW NAME

SONY EMCS (M) SDN BHD
(SOEM)

MANAGING DIRECTOR (SOEM) 2004

MR. T. KIKUCHI

8
 Illustration 2.3: KL Tec at Bandar Baru Bangi

2.6 SOEM EXPORT

 High Quality Products are produced and distributed in Right Quantities to the
Right Locations at the Right Time!

Figure 5.0: Country of SOEM Export

Sony EMCS (Malaysia)

9
 SOEM started product design of personal audio products, such as walkman and
CD walkman in 1990. And then TV in 1992, and Home Audio and Video
products in 1994.Lastly from 2006, SOEM started LCD TV design.
 LCD TV, DVD player, Home Theater and Receiver are currently 100% designed
by SOEM. Other categories also are designed by us.

Sony EMCS (Malaysia)

 We started product design of personal audio products, such as walkman and CD

walkman in 1990. And then TV in 1992, and Home Audio and Video products in
1994. Lastly from 2006, we started LCD TV design.

Sony EMCS (Malaysia)

2.6.1 Customer Service Activities

 SOEM provide excellent Technical Support for all our Service Centers in Pan
Asia so that they can provide fast response for our customer claims. In addition
that SOEm are doing technical information service.

2.7 ETHICAL AND CULTURE OF WORK

To build in good quality into SONY products, they promote People

Innovation “Hitozukuri”. They are making people with high discipline and Habitual
Behavior.
o First one is meeting in line.
o Second is confirmation of job.
o Management also gives high motivation to people with morning greeting.
o Finally they are confirming the quality at spot.

Spirit Burning (Quality People, Quality Products)

It is necessary to have a passion for making good quality in products so that we are
doing spirit burning and exercise every day.

10
2.8 COMPANY ORGANIZATION CHART

Video Sector Video Design

Key Component

TV Sector

TV Engineering

R&D 1

VP Sector R&D 2

R&D 3

Quality Assurance

MCM Asia

KL Manufacturing Manufacturing Common

Centre
TV Production

DVD Production

Managing Director Auto Mount KL Auto Mount

Centre

Quality Reliability-KL
Quality Assurance/
Customer Service
Centre Customer Service-KL

Procurement
Procurement Centre

Accounting & Finance

Corporate Planning
Business Strategy
Centre Production Control KL Tech

Information Technology

Human Resources

Human Resource & General Administration

General Affairs Centre
Shared Services

11

Sony EMCS (M) KL Tech Organization Chart

 2.9 TELEVISION QUALITY REASSURANCE (TV QR) ORGANIZATION CHART

12
 CHAPTER 3

REPORT ON JOB/TASK/ASSIGNMENT/PROJECT

3.1 DEPARTMENT OBJECTIVE

The main purpose and activities of this department is more to testing and
measurement for each new model TV. Each new model TV must pass all kind of
testing under TVQR before it can be ship to buyer country. There are four small
groups under TVQR which is Product Safety (PS), Quality Control (QC), Reliability
& Engineering (RE), and lastly Quality Promotion (QP)

3.2 PRODUCT SAFETY

Product safety is one of four groups in TVQR. Purpose of this group is to

ensure the safety of the entire new model TV before it can be sell to customers.
There are five types of testing that will be done by PS group like leakage current,
RIPR, power consumption, fool proof, and smell test & outgas.

3.3 LEAKAGE CURRENT

The objective is to protect electric shock when customers touch any terminal
at LCD set. To check SOEM LCD TV complies with the RIPR requirement.

3.3.1 PROCEDURE

1. Setup The Equipment (Scope meter, leakage current jig)

2. Change the setting (frequency & voltage) at the power amplifier

3. Measure current from different terminal ( RF, Video 1, Video 2, and DVD)

4. Repeat the process using different setting on power amplifier

5. Record & calculate the current leakage manually in the check sheet.
6. Leakage Current value which is over than 10% than design data should be
highlighted to designer.
7.

13
 Leakage current jig
Scope meter

Power amplifier EUT

Illustration 3.0: Step Using Equipment

3.3.2 WHY USING SCOPE METER

 Able to give consistent reading from power amplifier.

 Value will be shown by a graph at the correct frequency.

 To get accurate and parallel reading compared with design.

 The reading will not influence any noise NF supply.

14
3.4 REALIBILITY INCIDENT PREVENTIVE RULE

The objective is to ensure TV Business Group products comply with safety

regulation in the RIPR.

3.4.1 SCOPE

 Applicable to all product related to TV Business Group Products, including

products designed all produce at parties other than Sony.
 Component and sub-assembly use for products must satisfy all the
requirements describe in RIPR

3.4.2 STAGES

Start

General
Inspection

Mechanical Part
Checking

Electrical Part
Checking

Leakage
Current

General
Inspection

End

15
3.4.3 ELECTRICAL PART

PWB (Printed Wiring Board) structure.

 Check the component based on the check sheet.
 Eyelet & normal solder.
 Clearance.
 ID marking.

3.4.4 MECHANICAL PART

Consist of plastic part.

 Rear Cover, Neck, Stand Base.
Check External part of TV.
 Dust, scratch, finger print, paint peel.
 Gap.
Ensuring the PN same as check sheet

16
3.5 POWER CONSUMPTION

The objective is to ensure Sony LCD TV energy rating is according to the

value declared to the country's government.

3.5.1 RULE

1. New model introduced: 3 units per model before Shipping Confirmation

Meeting.
2. Current model: 1 unit per model per 3 months.

Malaysia

Australia & New Zealand Japan

Illustration 3.1: Energy Rating Label

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3.6 FOOL PROOF

The objective is to verify the label on the set with the reference.

3.6.1 PROCEDURE

Take picture of the following items:

 Combi Label
 Carton Logo
 Carton Dimension
 Pop Sticker
 Caution Label
 Warranty
 Battery
 AC Cord
 E-Pop
Transfer the entire picture to the computer.
Compare with the reference.

Illustration 3.2: Label Need to Take Picture

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3.7 SMELL TEST & OUTGAS

Preliminary round
 To select members who are able to identify smell test sample.
 Each member will be given 5 samples per rounds.
 Identify which sample number has SMELL.
 Circle the sample number on the test sheet.

Final round
 To identify the variance between new tester and current tester and calibrate
new tester judgment
 Each member will be given an air sample collected from the smell test
chamber.
 Evaluate the smell of the air sample according to the evaluation sheet

3.8 SMELL TEST & OUTGAS PURPOSE

Smell test objective is to measure the strength of smell coming from TV

within limit in order not to make user to fells uncomfortable.

Outgas objective is to ensure customers health is not adverse by monitoring

the outgas LCD TV emit has the target chemical within limits set.

19
3.9 SMELL TEST & OUTGAS EQUIPMENT LIST

BLOWER

DUMMY
SCREW

SCREW
DRIVER

SMELL
CHAMBER

20
VACUUM
BOX

ELASTIC
RUBBER
TUBE

SUCTION
PUMP

ODOR
BAG

21
RUBBEER
COVER

SORBENT
SILICA &
COCONUT

MINI PUMP

22
 3.10 SMELL TEST & OUTGAS TESTING PROCEDURE

 Check TV set model name, destination, product no, and serial no. make sure
it same with production schedule.

DESTINATION MODEL
NAME

PRODUCT NO

PP GREEN
LABEL
SERIAL NO

 Use blower to move the tape from carton. The reason why use blower is to
ensure the carton not damaged during the tape removal process.

23
 By using both hands, lift TV carefully from the carton to prevent defect from
occurring.

Lift Using
Both Hands

 Assemble the stand base with TV by using dummy screw and screw driver.
This to ensure the TV can stand alone during testing.

 Tag the TV and carton with tagging number for identification. This tagging
usage is to easier the tester to find the carton after finish testing.

SAME TAGGING NUMBER, FOR

EASY IDENTIFICATION

24
Put the TV into smell chamber.

Illustration 3.3: TV in smell chamber

 Switch On the TV and setting TV to find signal. Make sure signal TV is in all
white condition.

Illustration 3.4: TV in all white signals

25
Close the chamber tightly to prevent air from coming out. After the chamber being
close, aging the TV for 2 hours.

Illustration 3.5: Chamber tightly closed

Illustration 3.6: TV Aging process in chamber

 After two hour, take the smell test sample using Odor bag, follow by take
outgas sample using sorbent silica and coconut.

26
3.11 HOW TO SETTING TV

 Select language.

 Select area

 Select type of use

27
 Select position

 Start auto tuning

 Tuning in progress

28
 Tuning finished, it shown number of program found

 Set day and time

 Setup complete

29
3.12 TAKEN SMELL TEST SAMPLE

 Use odor bag to take the sample

 Put odor bag inside the Vacuum Box

 Adjust the vacuum box button to on position like below

30
 Make sure the tube is connected from chamber to vacuum box, from vacuum
box to suction pump

 Switch on the pump, fill the Odor bag with smell sample until half full

 When finished, close the Odor bag with rubber cover

31
 Enter the details of such a model, destination, serial no, and date on the
paper provided. Attached the paper on the Odor bag.

 Fill at least four Odor bag with smell test sample. Give the sample to qualift
TVQR member for evaluation.

32
3.1.3 TAKEN OUTGAS SAMPLE

 Using two types of sorbent which is silica and coconut

 Take the sorbent and break both end of sorbent using cutter

 Inside end of sorbent with cotton into the chamber tube, and the other end of
sorbent to mini pump tube.

33
 Setting the mini pump according to sorbent specification

 Pump Setting

34
 Take the sample using mini pump

 Each sample had to be taken about ½ hour

 When finished, close the sorbent using masker tape

 Keep sorbent containing outgas sample into the fridge.

35
3.14 TYPE OF NEW MODEL

There a two types of new model for SONY TV production. The first new
model is Pre Production (PP) stages, and the second one is Mass Production (MP)
stages. The different of both new models can be seen at illustration below.

GREEN
LABEL

Illustration 3.7: PP Stages Label

BLUE
LABEL

Illustration 3.8: MP Stages Label

36
There are also a model know as current model.

NO LABEL

Illustration 3.9: Current Model Label

37
3.15 KAIZEN

Kaizen mean improvement or change for better. Kaizen can be practice to

improve process in manufacturing, engineering, supporting business, and
management. Kaizen had been practice at all SONY factory for a long time.

3.15.1 KAIZEN AT SONY TVQR

Kaizen had been practice many years at TVQR. It had become part of
tradition at TVQR. There are two types of kaizen that been practice at TVQR which
is; physical kaizen and internal kaizen. Physical kaizen is more to thing we can see,
touch, and use. For example angle jig. On the other hand, internal kaizen is more to
improve management system.

Tuesday had officially selected as a kaizen day at TVQR based on Zero

Defect Day (ZDD) are also on the same day.

38
 CHAPTER 4

CONCLUSION

Industrial Training gives an early exposure of the working environment,

practical aspect of what had been learned and application of those theories that had
acquired so far. It also develops the students working abilities, competence, and
interpersonal skills. In addition, it gives exposure to student and some idea of the
future seeking jobs.

Industrial training also exposes the student to rules, regulations, and safety
practices in an industrial environment. Besides, it develops the student’s sense of
team spirit in accomplishing a common goal. Student can have high confidence level
and experiences to face the challenging and demanding world.

In a conclusion, the training was very interesting for me since I had gained a
lot of knowledge and experience. I had learned how to do testing and troubleshooting
the problem, dissemble, cleaning, inspection, repair, assemble and testing in the
TVQR department. Although I had faced some difficulties during the training, I am
still glad to have a new experience in my life. Again, it is my great pleasure to
acknowledge and thank to all that have contributed to my industrial training report.

39
 RECOMMENDATION

There are some suggestions that I would like to propose in order to make this
industrial training become more motivating and practical.

I would like to suggest to the KKTM to give more hands on skills during the
lab session so the student will have high level of confidence to perform any task
before they go for industrial training. The proper guidance on how to do the
presentation and report should also be given.

In addition, it is better to have the proper manual prepared by the company to

guide the student during their practical training. They also can provide a project that
can be accomplished by the student so the student becomes clear on what task they
are going to carry out.

40
 REFERENCES

 http://www.sony.com.my/section/corporate
 http://www.sony.com.my/article/234686/section/sonysstory
 http://www.sony.com.my/article/234687/section/productmilestones
 http://www.sony.com.my/article/239931/section/overview
 http://www.sony.com.my/article/239946/section/sonycompanyoutline
 http://en.wikipedia.org/wiki/Sony
 http://en.wikipedia.org/wiki/Luminance
 http://en.wikipedia.org/wiki/LCD
 http://en.wikipedia.org/wiki/LED_TV
 http://en.wikipedia.org/wiki/CCFL
 Industrial Training Student Handbook & Logbook, Kolej Kemahiran Tinggi
Mara
 QR JOB FUNCTION TRAINING SYLLABUS
 APPENDIX 1: BZ212 MECHANICAL FEATURES
 THE GENERAL-DAVID SARNOFF AND THE RISE OF THE
COMMUCATIONS INDUSTRY
 PIONEERING IN TELEVISION
 RCA,Robert Sobel, Stein & Day 1986,282pp.

41
 CHAPTER 5

APPENDIX

Illustration 5.1: TVQR North Wing (Product Safety & QC) Layout

42
 APPENDIX 2

Illustration 5.2: Proposed Area for General Expenses

43
 APPENDIX 3

Illustration 5.3: Set Information Form

44
 APPENDIX 4

Illustration 5.4: Jon Item Form

45