INDUSTRIAL TRAINING REPORT

FESTO SDN BHD

10, PERSIARAN INDUSTRI,
BANDAR SRI DAMANSARA,
52200 KUALA LUMPUR,
WILAYAH PERSEKUTUAN KUALA LUMPUR



HAIZUL HAIQAL BIN ZULFAKA
2011223714





Faculty of Mechanical Engineering
UNIVERSITI TEKNOLOGI MARA





SEPTEMBER / 2014







ABSTRACT

Festo Sdn Bhd, located at Bandar Sri Damansara. This company is one of
Festo branches worldwide and providing solution for our clients based on
information gathered as well as specifications given. Established since 1925,
Festo continues to helps any industries for their improvements as well as
increasing productivity and effieciency. This report consists the background
of the company, Festo and its work culture. The next part is regarding the
lesson learnt and experience gained by author together with the main
activities and training involved during this Industrial Training Programme. A
brief description about the main tasks and jobs done are mentioned in this
section. And the last part, author will cover on discussion on sustainability
and its common practice. At the end of the report, list of references and
appendices are attached. Finally, the report wraps-up with a few closing
remarks and conclusions from the experience together with the summary and
recommendation for future betterment of Industrial Training Programme.



















Table of Contents

1.0 INTRODUCTION .................................................................................................. 1

1.1 History ................................................................................................................. 1
1.2 Structural of main activity .................................................................................. 1
1.3 Objectives ........................................................................................................... 2
1.4 Scope of training ................................................................................................. 2

2.0 INDUSTRIAL ENVIRONMENT .......................................................................... 3

2.1 Work Ethics ........................................................................................................ 4
2.2 Occupational Safety and Health Environment .................................................... 5

3.0 INDUSTRIAL EXPERIENCES ............................................................................. 6

3.1 SKILLS GAINED .............................................................................................. 7
3.1.1 Technical Skills .......................................................................................... 7
3.1.2 Communication Skill ................................................................................. 7
3.1.3 Time management ...................................................................................... 8
3.2.4 Initiative ..................................................................................................... 9

3.2 Training schedule .............................................................................................. 10

3.2.1 Drawing .................................................................................................... 10
3.2.2 Assembly and Testing ............................................................................. 11
3.2.3 Site Visit ................................................................................................... 13
3.2.4 Preparation Manual .................................................................................. 13
3.2.5 Professional Training ............................................................................... 14

4.0 INDUSTRIAL PROJECT ..................................................................................... 18

4.1 Overview of the project .................................................................................... 18
4.2 Involvement with project .................................................................................. 18
4.3 Relationship to Mechanical Engineering .......................................................... 21

5.0 SUMMARY .......................................................................................................... 22

5.1 Recommendations ............................................................................................. 23
5.1.1 Recommendations for the host company ................................................. 23
5.1.2 Recommendations for the university ....................................................... 23

6.0 REFERENCES ..................................................................................................... 24

7.0 APPENDICES ...................................................................................................... 25





List of figures

Figure 1: Festo official logo ........................................................................... 1
Figure 2 : Controller design drawn based on specifications given. ............. 10
Figure 3 : The drawings consists of exterior and interior layour for the
panel. ............................................................................................................ 11
Figure 4: Drawing of XY Gantry. ................................................................ 12
Figure 5: Final assembly product. ................................................................ 12
Figure 6 : User manual for CMMS-AS-C4-3A-G2Professional Training ... 13
Figure 7: Preparation of compressed air ...................................................... 15
Figure 8 : Festo air regulator and filter ........................................................ 15
Figure 9 : 3/2 way valve ............................................................................... 16
Figure 10 : Introduction to Pneumatic P111 ................................................ 17
Figure 11 : One of the drawings for Doeka Asia ........................................ 19
Figure 12: Internal part including PLC, valves and servo motor. ................ 20

















1


1.0 INTRODUCTION

1.1 History

Figure 1: Festo official logo
Festo is a privately owned German industrial control and automation company based
in Esslingen am Neckar, Germany. Festo was founded in 1925 by Gottlieb Stoll and
Albert Fezer. Initially, it manufactured wood cutting tools and later diversified into the
automation industry. A noteworthy early product was the first portable, gasoline-
poFestored chainsaw.Today, Festo is a leading world-wide supplier of automation
technology and the performance leader in industrial training and education programs.
Festo has a world-wide presence, in 61 branches and 250 sub-branches. In fact, with a
great track record, Festo achieved such a huge achievements by far.

1.2 Structural of main activity

Festo is a worldwide leader in automation and a world market leader in technical
training and development. There are 2 main business sector that involved in Festo.

Automation: Solutions for factory and process automation
Festo develops pneumatic and electrical drive and control technology for factory and
process automation from individual catalogue products to ready-to-install systems.
Didactic: Partner for technical education
In the field of industrial training and development, we bring together more than 40
years of experience and method skills with a comprehensive range of learning
systems.
2


1.3 Objectives

1. To expose the students to actual working culture and industrial practice.
2. To allow the students to extend their theoretical knowledge into practice.
3. To motivate students to practice the right working attitudes and
professionalism to increase their employability potential.
4. To provide student with basic skills of technical staff.
5. To enhance student with application skills of engineers and management.
6. To expose students to safe practices and regulations in the industry.
7. To instil the qualities of integrity, responsibility and self-confidence.
8. To assess student ability and competency in their preparation to join the
workforce upon completion of their studies in UITM.

1.4 Scope of training

Drawing
Electrical circuit, Controller design, Panel Layout
Preparation manual and documentation
Servo Motor Controller, List of components
Assembly process
Air Lift control box, Filter Regulator, XY Gantry
Software
AutoCad, Trilogy, Festo Configuration Tool (FCT), EPlan
Testing
Vertical Steriliser, Pressure regulator, Pneumatic components
Site Visit
Nippon Paint Shah Alam, Doeka Asia Subang Jaya
Professional Training
P111- Introduction to Pneumatics



3


2.0 INDUSTRIAL ENVIRONMENT

Aside from the job scope itself, one factor that significantly influences how employees
feel about work is the environment. By work environment, everything that forms part
of employees involvement with the work itself, such as the relationship with co-
workers and supervisors, organizational culture, room for personal development, etc.
A positive work environment makes employees feel good about coming to work, and
this provides the motivation to sustain them throughout the day.

In Festo, team work is very important and the main element that was practiced since
long it was established. They are working on valueing diverse people, ideas,
backgrounds and experiences. For example, when completing any project, what author
see is everyone in the team working together, discussing, changing and sharing ideas
and data even though we come from very differ background from project manager,
program engineer as well as system engineer. None of the work is owned by one
specific person but instead act as a team in which we are open and accept ideas as well
as input from each other. By working in a team, we maintain teamwork even when
things are going wrong and we value the teamwork culture. Teamwork is rewarded
and gets recognitions from our success in which we get it from teamwork culture
instead of doing it alone. Besides, risk and uncertainty can be reduced by this method
thus the results would be greater.

During early period, author have been introduced to various departments in the
company. Author also experienced the meeting environment for the first time in his
life. This experience is priceless to author especially, because author can observed
how the meeting were conducted in the real working life. In fact, author learnt a real
working life in this company. The situation in this company is very differ compare to
university, simly because a different interest. Author have learnt various knowledge,
applying all those into this past twelve weeks.








4


2.1 Work Ethics

Festo Group is an internationally active family owned company with a long-standing
tradition and a high reputation among its business partners and employees. Festo
Group emphasizes integrity and has a high standard with regard to ethics and legal
compliance. With this Code of Conduct,we acknowledge ourresponsibility towards
our commercial and social environment, including our employees working around the
world. As this Code of Conduct must be follows by all of Festo staff, failure to follow
this code will cause severe consequences for the group and results in disciplinary
action against the defendant. The Festo Code of Conduct is an illustration to further
explain the provisions of the Code as applied in all the countries in which Festo
conducts operations. It does not describe all applicable laws or Festo policies, or give
full details on any particular law or policy. It does not constitute legal advice. It does
not constitute or create a contract of employment. Festo reserves the right to modify,
revise, cancel or waive any policy, procedure or condition without notice and without
revision of the Code.

The employees at all times are required to:
Conscientiously maintain the highest degree of integrity,
Always exercise proper care and judgment
Avoid conflicts of interest, and
Refrain from taking advantage of our position or exercising our authority to
further our own personal interest at the expense of Festo
5


2.2 Occupational Safety and Health Environment

As world leading company, Festo is committed to the highest safety and standards. In
line with their commitment, they are enhancing the governance of occupational safety
dan health environment ( OSHE) .Our vision of quality and the environment is an
attainable image of a worthwhile future and gives meaning to our actions

The main objective is to elevate Festo OSHE performance, reduce business, risks and
exposure, and maintain consistency in the implementation of OSHE standards and
implementation. Continuous enforcement and consistency in following the Standard
Operating Procedure (SOP) recommended are vital in strengthening their OSHE
implementation which seeks to establish a pervasive OSHE culture in the renowned
corporation.

In strengthening product stewardship practices across Festo, they have begun
developing and rolling out implementation plans throughout the downstream business.
They have certain measures to manage fatigue at the workplace and a fitness to work
guideline has been developed by Festo to better protect the health and safety of their
workforce and communities where they operate.


















6

3.0 INDUSTRIAL EXPERIENCES

There is a quote from E.F. Schumacher, An ounce of practice is generally worth more
than a ton of theory, which is enough to describe what author have gone through
during this Industrial Training. This is one of the greatest experiences that author have
had for the entire life. It is here that author learned and gained so much experience that
author could not have from the classroom setting. Author learned what it was like to
work in a department with tasks that are due at a minutes notice and how to handle a
large workload. This training showed to author, if not highlighted, that author chose
the right career path and can happily live with it for the rest of life.

Since author attached with Festo Sdn Bhd, author have learnt various knowledge
regrading the automation processes as well as some sort of electrical engineering. This
training program helps in order to get into pneumatics system in a larger perspective.
Thus,with such a broad knowledge, author believe that this information might helps
for future referrals.





















7

3.1 SKILLS GAINED

3.1.1 Technical Skills

Working with Festo gave author a lot of resources for learning as well as to enhance
my skills and improving my knowledge. Apart for the theoritical part, Festo always
provide the best technical practice for its staff as its a continueos learning process. As
a Festo is a leading company in automation process, thus the quality of our services
have been a top priority for all of us. Although the task given may difficult and quite
advance, but all the problems and projects have been solved within the timeline given.

3.1.2 Communication Skill

Communication is the foundation of any successful business or organization. We
know that the development of communication skills in management is critical for
productivity, employee engagement, customer satisfaction and profitability. As an
trainee, author knows that the ability to communicate effectively can greatly affect my
career development in the future workplace. Author employer highlighted two
communication skills needed by all workers: written, oral, and technology.

Written Communication

Oral communication is the mode of choice in most workplaces today; the paper memo
is dead, replaced by voice mail, informal conversation, and sometimes E-mail or fax-
mail. But two writing tasks still loom before the entry level worker: Writing reports
and filling out forms. For example, many companies these days are seeking
certification in a variety of world class standard programs, which require extensive
documentation. Workers have to fill out reports that ask them to describe exactly what
they do and how they do it. In my case, author need to record everything that author
did in logbook daily and make a report at the end of Industrial Training.


Oral Communication

We can see that employees still need written communication skills. Yet interpersonal
oral communication skills are the ones most prized by employers in the new informal
workplace atmosphere. Author could see some of the workers here prefer to test the
ability of an intern to follow oral directions. A lot of tasks were actually given orally,
which is more effective and more understanding.
8


3.1.3 Time management

The main reason time management is important is to control over the amount of time
spent on certain activities thus effectiveness, efficiency and productivity can be
achieved. These are some certain steps taken by author in accomplishing the target.

Plan each day Write to do list
Punctuality Always come early to the office, meeting or any events.
Prioritize the tasks Prioritizing work help in ensuring time and energy are
well spent on something truly important instead of unimportant tasks which
are time consuming.
Take the time needed to produce a quality job Avoid error which can
easily waste the valuable time. Do frequent quality check (QC)
Take a break when needed Too much stress can results in failure in trying
to get organized. When author need a break, author take a walk and make
some coffees to refresh my mind.


















9

3.2.4 Initiative

Showing initiative is a must-do in demonstrating our value at work. It correlates
strongly with personal achievement and professional development. It is the act of
taking personal responsibility for our own growth, and it is a clear sign of our capacity
to develop as a leader.
These are among the initiatives that author took during the internship:

Do Your Current Job Well

Employers today are seeking individuals who want to do their job to the very best
of their ability every day. Author learned that every task given need to be carried
out efficiently and completed within the time frame allocated. This may mean
working some overtime, including evenings. For example, all tasks assigned to me
during the training are done based on my knowledge limit. Although there is a
limit, author tried to take own initiative to gain new knowledge from the engineers
here..

Going The Next Step.

It is critically important to do the job well. The key to success is going the next
step. For example, as a trainee, author often come into the situation where author
need to use a software tool or application. For the first time, it is appropriate to ask
for help from the experts, but if it is constantly done, self-development skills will
be stop growing and become fading. There are always a few choices whether to
read the training manual or refer to the on-line help facility, and attempt to solve
this problem on our own. Author is eager to explore new things and think that is
why author was destined to be in System Engineering department. To employer,
initiative is "going the next step" without being told to do so








10

3.2 Training schedule

3.2.1 Drawing

Autocad is one of engineering programe that widely use in industry. This software
allows users to draw any types of drawing either is 2D and 3D as well. For instance,
author have use this type of programme to complete the task given by authors
department. This programme is easy to use, understandable as well as suitable for any
type of engineering fields.

Mounting Panel
This task was assigned by Design Engineer, Mr Hanizam. As our services required
information from our customers, hence we have to customize some of the components
that are not available by Festo. Basically, any non-electronics components are
customized based on our clients specifications. In fact, we have to collect as much as
information needed before proceeding to customization process. Based on our
Standard Operation procedure (SOP), all the drawing must be approved by our
engineer, before proceeding to any further processes.


Controller Design
As a one stop solution provider for pneumatic and automation industries, Festo have
provided the best service for their customers. Practically, Festo have to extract our
customers idea and will elaborate the ideas by infusing it into our design. For this
project, author was assigned to draw control panel (exterior) for one of the project.
The drawing have been drawn by using Autocad software and have been approved by
our respective enginer.


Figure 2 : Controller design drawn based on specifications given.
11


Panel Layout Design
Festo always dealing with pneumatic and automation process, thus we have to come
out with a solution,complete with the drawings, just to simplified all the processes. As
for this task, author was assigned to draw internal plan layout for one of the panel.
This project were completed for B. Braun, company that focussed on pharmaceutical
industry.


Figure 3 : The drawings consists of exterior and interior layour for the panel.



3.2.2 Assembly and Testing

As most of Festo components arrived in single piece, thus it needs to assemble before
its handover to our customers. Basically, all we have to do is assemble all the
components based on the design given. For example,we have to connect all the wiring
into the pneumatic system to form electro-pneumatic. Apart from that, some of the
assembly process have to be done at customers site due to limitation of space, time as
well as extension of our customers project.
12


Figure 4: Drawing of XY Gantry.

Figure 5: Final assembly product.













13

3.2.3 Site Visit

As solution provider, Festo always look forward towards their customers. During
training program, author have been went a visit to two places, Doeka Asia and Nippon
Paint. These were new experiences as author could see how things works as well as
gained new knowledge. This experience some sort of eye opener regarding real
working life in engineering field.

Doeka Asia
This was the first site visit experienced by author. As requested by Mr Liew, author.
This project will be elaborate as Industrial Project.

Nippon Paint
Author followed Mr Bazli to complete the project. Author have learnt on how to read
and key in input-output (i/o) adress. Author was assigned to helps Mr Bazli to
complete commisioning process, including to check either the components works
properly based on program or not. Some amendments have been changed due to
certain problems occured.

3.2.4 Preparation Manual

During this training period, author was assigned by Mr Liew Sip Hoo to prepare a
user manual for CMMS-AS-C4-3A-G2 Servo Motor Testing Using FESTO Controller
Tool (FCT). Basically, author have done a simulation based on the program for a
testing purpose. The software use is Festo Controller Tool (FCT) that provided by
Festo. The complete manual is attach in appendix area.



Figure 6 : User manual for CMMS-AS-C4-3A-G2Professional Training
14

3.2.5 Professional Training

Pneumatics is a section of technology that deals with the study and application of
pressurized gas to produce mechanical motion. Pneumatic systems, that are used
extensively in industry, and factories, are commonly plumbed with compressed air or
compressed inert gases. This is because a centrally located and electrically powered
compressor, that powers cylinders and other pneumatic devices through solenoid
valves, can often provide motive power in a cheaper, safer, more flexible, and more
reliable way than a large number of electric motors and actuators.


In major applications compresssed air is used for one or more of the following
functions
To determine the status of processors (sensors)
Information processing
Switching of actuators by means of final control elements
Carryinng out work

This course emphasized on basic applications of pneumatics mechanism including the
symbol, practical as well as other information needed for a beginer. As for author who
has no experience in pneumatic program, this course have been a good starting point at
all. Author gained a lot of knowledge through this course based on these activities:

Theoritical Part:

15


Figure 7: Preparation of compressed air

Figure 8 : Festo air regulator and filter











Inlet Filter
Air Compressor
Air Reservoir
Air Dryer
Air Filter
Pressure Regulator
Air Lubricator
Drainage Point
16


Effects of unclean compressed air
Corrosion
Loosing the port
Decrease the efficiency of valve
In addition, author have learnt various components for pneumatics from 2/2 valve to
pressure sensor. In fact, author have been able to identify the type of valve based on its
symbol and its characteristics.

The way to read valve:


Figure 9 : 3/2 way valve

To read the valve, the formula as below:

No of port / No of position



















17

Practical
Author have completed several problem-based questions during the course That is
included on applying all the theory into a real life situation. One of the problem is to
create a washing machine mechanism by using pneumatic components.



Figure 10 : Introduction to Pneumatic P111












18


4.0 INDUSTRIAL PROJECT

DKA is a leading supplier for Industrial Automation solutions. The company was
founded in 1966 in Rimbach/Germany as a local machine supplier. Within short
DOKA has become a global player with customers in over 50 countries
worldwide.Their product range include automated machines and technical solutions
for different kind of manufacturing industries. DKA is for example world-wide
leading for fully- and semi automatic machines for particular medical products.

4.1 Overview of the project

Doeka Asia is located at Subang Jaya,Selangor emphasizes on manufacturing the
machine for their clients. As an expertise, Festo provide a full co-operation with
Doeka Asia for their project,namely as Condom Testing Machine With Servo. This
machine practically use in order to check the maximum force that can be applied on
the condom. The elasticity of the condoms should meet the requirement as stated by
our clients. As for this project, Festo are responsible to completing the project,
including designing the external and internal parts, electrical circuits as well as
commisioning programme.

4.2 Involvement with project

Electrical Drawing

For this project, author was assigned to update electrical drawing based on
amendments done by our client. This changes have been made due to several problems
occured during testing proces including to improve the efficiency and capability of the
machine. As authors background is Mechanical Engineering, this task somehow quite
challenging because author needs to understand on how to draw, read and manipulate
electrical circuit.








19


Throughout the process, Mr Liew helps author a lot in terms of all difficulties
happened. In fact, with his guiding, author are able to understand the whole concept of
electrical drawing. As Mechanical student, author learnt on theory basis only in the
class. By involving this project, author had gain a lot of knowledge regarding
electrical components, circuit and connections.


Figure 11 : One of the drawings for Doeka Asia
Site Visit
During first week of training period, author was assigned by Mr Liew to follow Mr
Ryan, to Doeka Asia, Subang Jaya. Practically, author helps Mr Ryan to complete
commisioning process of the machine. Through the experience, author have helps Mr
Ryan and Mr Liew to complete some wiring works including soldering. Mr Liew
explains to author on how the machine works as at the first glance, this was the first
time author went to site visit. Based on explainations by Mr Liew, author are able to
figure out how the machine works.


20


Figure 12: Internal part including PLC, valves and servo motor.

Mr Liew demonstrate regarding the operation of the machine. The software used is
from Germany, and its comes with multi-language option. Mr Liew teach Doeka Asia
representative to operate the machine. From author observations, the system used is
electro-pneumatic. As the visit were on early days, author somehow doesnt have a
broad knowledge on pneumatics system, fortunately Mr Liew have teach on PLC,
connection of pneumatics components and a lot of new knowledge.













21

4.3 Relationship to Mechanical Engineering

In order to relate with Mechanical Engineering field, author believe that these
knowledge will be very usefull for a final year of studies. As this project combining
electrical, mechanical and pneumatics field, it such a good project that author involved
with. There will be a subject called Robotic and Automation that will be apply all
these theories including programming PLC, drawing electrical circuits as well as
connection between pneumatics components.

To make it short, this industrial project some sort of an eye opener for author to get
into pneumatics and electrical field. Author is interested in programming PLC,
configuring pneumatics components as well as by hybrid that knowledge with
mechanical field. Author is looking forward to configure at least one, and it will be
great and interesting if its work.























22

5.0 SUMMARY

The past twelve weeks of Industrial Training Programme have been very instructive
for author especially. Festo has offered author such an opportunities to learn and
develop in many areas. Author gained a lot of experience, especially in the
Mechanical and Electrical field. It would help author to choose special topics in the
final year of studies. Author learnt a lot from the engineers that author have been
working with during Industrial Training especially Mr Liew Sip Hoo and other
engineers. All of them are very helpful in sharing their knowledge and experiences.
Work ethics, trends, technology and challenges that author may face in the future have
been exposed during the period of this training. It is really crucial to get familiar with
the industry as it is the first step to build the career in a certain field. In line with the
UiTM mission to produce well-rounded graduates who are creative and innovative
with the potential to become leaders of industry and the nation, author are able to
achieve the objectives set by UiTM in this period of training.

Last but not least, it was a great opportunity for developing personal networking
activities and making contacts which may prove of value in the near future and to
work with a fantastic team of very hard-working team.


















23

5.1 Recommendations

5.1.1 Recommendations for the host company

Festo is a great learning company for interns. Author would recommend specifically to
the System Solution to keep hiring interns of Mechanical background since it will be a
advantages for them. It will help the students to build and improve skills with the
knowledge they gained from their studies, as well as strengthen the relationship
between industry and educational institute.

5.1.2 Recommendations for the university

Weekly logbook Author suggest that the logbook should be filled weekly instead of
daily. Students need to get involve in a team project and other department tasks. So,
the workload is heavy, not just for us, but for the supervisor to check and verify.
Furthermore, it will steal the time that supposed to be spent to learn new things
throughout the internship.

Engagement with intern students Author would like to suggest for UiTM to conduct a
few engagement with intern students in their host company throughout the internship
to discuss the problem that may be faced and to ensure that the students keep on track
to achieve the defined objectives.
















24


6.0 REFERENCES

1. Peter Croser, Frank Ebel, Pneumatics Basic Level TP 101, Festo Didactic GmBH
& Co, 2000
2. G.Prede, d Scholz, Electro-Pneumatics Basic Level TP 201, Festo Didactic GmBH
& Co, 1999
3. Doeka Condom Testing Machine With Servo, Festo Sdn Bhd, Department of
Solution Engineering, 2014
4. http://www.festo.com/net/lt_lt/SupportPortal/default.aspx?cat=1527&tab=3&s=t




























25

7.0 APPENDICES