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UNIVERSITI TEKNOLOGI MARA

MEM560 MANUFACTURING PROCESSES

PROGRAM CODE

EM220

GROUP

EMD5M1A

LECTURER

ENCIK ABDUL GHALIB

DUE DATE

19th DECEMBER 2014

NO
1
2
3
4
5

STUDENTS NAME

ID NUMBER

MUHAMMAD HAZIM FAHMI BIN MOHD YAMIN

2012226818

MOHAMAD ZAID BIN MOHAMAD ZAILANI

2012241394

MUHAMAD SHAFIQ BIN SAUFI

2012876726

AHMAD HASSAN BIN MUHAMMAD MUHAYYIDIN

2013411786

MUHAMMAD SYAHIR BIN AHMAD ZABIDI

2013440952

Ma n u f a c t u r i n g P r o c e s s e s (MEM560)

INDUSTRY VISIT REPORT

Ma n u f a c t u r i n g P r o c e s s e s (MEM560)

Contents
1.0

DISTRIBUTION OF WORK AMONG MEMBERS .................................................................................. 4

2.0

Introduction ...................................................................................................................................... 5

2.1

COMPANY PROFILES ..................................................................................................................... 5

3.0

OBJECTIVES OF THE VISIT .................................................................................................................. 6

4.0

FINDINGS ........................................................................................................................................... 7

4.1

MANUFACTURING PROCESS ......................................................................................................... 7

4.1.1

INCOMING ............................................................................................................................. 8

4.1.2

STAMPING ............................................................................................................................. 9

4.1.3

WELDING ............................................................................................................................. 11

4.1.4

ASSEMBLY ........................................................................................................................... 12

4.1.5

QUALITY CONTROL .............................................................................................................. 14

4.1.6

OUTGOING .......................................................................................................................... 15

8.0

REFERENCES .................................................................................................................................... 18

9.0

APPENDICES .................................................................................................................................... 19

Ma n u f a c t u r i n g P r o c e s s e s (MEM560)

1.0

DISTRIBUTION OF WORK AMONG MEMBERS


MOHAMAD ZAID BIN MOHAMAD ZAILANI

objectives
stamping
SOP

MUHAMMAD HAZIM FAHMI BIN MOHD YAMIN

Manufacturing Process
apendices

MUHAMAD SHAFIQ BIN SAUFI

intro
Assembly

AHMAD HASSAN BIN MUHAMMAD MUHAYYIDIN

outgoing
references

MUHAMMAD SYAHIR BIN AHMAD ZABIDI

Incoming
Quality Control

Ma n u f a c t u r i n g P r o c e s s e s (MEM560)

2.0

Introduction
2.1

COMPANY PROFILES

Established over two decades ago, in the year 1988, Autokeen Sdn. Bhd. is a
private limited company specializing in metal parts manufacturing and assembly
specifically for the automotive industry, among a host of other products and services
offered. With a paid-up capital of RM5 million, and strategically located in the industrial
hub of Shah Alam, Malaysia, Autokeen has carved a niche for itself and is recognized as
Malaysias prominent manufacturer of automotive metal parts.

Figure 1 : Autokeen building

It prides itself for its strategic partnerships with automotive industry giants Proton
and Perodua, for the manufacture and development or new car models.
Twenty five years of strategic planning, steady growth, and complete customer
satisfaction have ensured that Autokeen has emerged as a leader in the industry. The
company continues to diversify and grow through previous and existing customers, who
have benefitted immensely from the high quality products and services provided by the
company, as well as new customers who eagerly trust Autokeen with their requirements.
The finest workforce coupled with the latest technology in a state-of-the-art
manufacturing facility enables Autokeen to provide its customers with products and
services that consistently exceed their expectations. Autokeen design, develop, engineer
and manufacture high quality metal stampings and assembly for the automotive industry.

Ma n u f a c t u r i n g P r o c e s s e s (MEM560)

3.0

OBJECTIVES OF THE VISIT

The objectives of the visit are:

1) To understand the processes involved in details about producing a high precision product.

2) To observed the working environment in the industries regarding mechanical.


3) To fulfill the requirement needed in the manufacturing course subject in the Mechanical
Engineering Faculty

Ma n u f a c t u r i n g P r o c e s s e s (MEM560)

4.0

FINDINGS
4.1

MANUFACTURING PROCESS

There are so many product that were manufactured by Autokeen where mostly parts of a
car. Beside that, they also manufacture a dies but only for small size since there are limitation of
their facility . There are some die used in this company which it can perform several process.
During in this visit we had choose one product to see how it being manufactured. So we had
choose an Proton Alza parts named REINF S/A DASH PANEL C/MBR. To produce this part
of Proton Alza, it will go through several processes such stamping, welding ,assembly and
quality work inspection also being perform for all subs part before delivery.

Incoming
Stamping
Welding
Assembly
Quality control
Outgoing
Figure 2 - Manufacturing step

Ma n u f a c t u r i n g P r o c e s s e s (MEM560)

4.1.1

INCOMING

There are two types of incoming into the production line which are material or
secondtier. The secondtier incoming is where the vendor sent the half-ready product for the
factory to weld and assemble to get the finished product. The secondtier incoming is directly sent
to production lines which are welding and assembly.
As for the incoming material, it can be divided into two forms which are coil and strip.
The examples of incoming materials in the factory are mild steel, SPC, NTHD, SPD, SPDE and
SGACE. The incoming material must undergo stamping process before proceed to the
production line.
After stamping process, there are some products do not need to undergo welding process
but just proceed to assembly process. But there also some products that only undergo welding
process after stamping process and proceed to PDI. Other than that, there are also products that
need to undergo all the processes before it can be transport.
Usually, the suppliers supply the incoming materials 2 weeks earlier for the factory to
produce the products. The factory usually ordered more number of incoming materials or supply.
For example the D87A product, the number of products need for December are 10500 unit, the
factory will ordered 11000 unit in case of defects that may be happen during the production.

Ma n u f a c t u r i n g P r o c e s s e s (MEM560)

4.1.2

STAMPING

There are three types of stamping machine available in Autokeen factory which can be
categorize by the size of the product small, medium and large. Dies price between RM100,000 to
RM200,000. One part of product usually will go through several stamping process where each
stamping are different process such a bending, pearcing and blanking process. The
manufacturing process of REINF S/A DASH PANEL C/MBR begin with Raw plate material
where will through stamping process. Stamping process started with part drawings or CAD data
design provided by customers for small to medium press machines. Small die were made by
using CNC milling. Design given by the customer are develop by Autokeen Design Engineer to
fabricate dies, assembly jigs, hand gauge, checking fixtures in support of the above parts
development.
REINF S/A DASH PANEL C/MBR consist of two part where one of it need to be
stamped by large press machine. The large press machines are very huge and it can do the
stamping processes with high pressure. The press machines are 1200 800 800 - 600 tan per
stamping. Those machines are CNC machining and can produce a lot number of products in a
time. The average time per one stamping process is 5 to 10 seconds. The large products are
obtained from these large press machines. Another part of this product need to be stamped by
medium press machines . The medium press machines are producing medium-size products. It is
also can do the stamping processes with relatively high pressure. The tan per stamping for
medium machines is 800 500 500 500 which the process per stamping is forming
trimming piercing shaping respectively. Most of the products from the Autokeen are undergo
medium press process. The medium machines are also CNC machining.

Ma n u f a c t u r i n g P r o c e s s e s (MEM560)

Figure 3 : Stamping machine

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Ma n u f a c t u r i n g P r o c e s s e s (MEM560)

4.1.3

WELDING

Welding is at the heart of metal fabrication . Autokeen provide welding and assembly
services of modular parts and components utilized by their clients, manufacturing sub assembly
of body panel metal stamping parts using various types of spot welding machines such as robotic
spot welding, stationary spot welders, portable, projection MIG welders. Since this part
consisting of three subs part, welding assembly need to be done to join them together. The
welding of the products can be divided into two which are Welding Stationary Spot (WSS) and
Welding Assembly Portable (WAP). The WAP is the welding at the spot which bolt and nut are
later to be attached. The types of welding that are used in the factory are Gas Metal Arc Welding
(GMAW), spot welding and spark welding. The spot welding is done by using guns which can
be divided into two which are S-gun or C-gun.

Figure 4 - S-gun and C-gun

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Ma n u f a c t u r i n g P r o c e s s e s (MEM560)

Figure 5 - welding point

4.1.4

ASSEMBLY

By using a jig, the products is being assembled. There are a lot of jigs needed in order to
produce one part. During this process, there are workers that checking the features of the
products. The standard tolerance is

when there are some products exceeded the

tolerance given, the products can be rework. Defect, usually occur during cutting process caused
by blunt cutting tool creating burr on cutting edge. This burr will creating a gap between two
parts of the product and spot weld could not be proceed, hence the burr need to be removed. The
burr removal can be done by using grinder.

Figure 6 - Burr

Figure 7 - Gap

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Ma n u f a c t u r i n g P r o c e s s e s (MEM560)

Figure 8 - Final Product

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Ma n u f a c t u r i n g P r o c e s s e s (MEM560)

4.1.5

QUALITY CONTROL

These are some aspect that are being evaluated, where workers need to ensure all of the aspect
were performed.

In this quality control specific on welding points, in this section worker needed to ensure 7 spot
welding were done at all red point below, 4 nut(M6) placed at yellow point, 2 bolt(M8) placed at grey
points, flange nut(M8) at blue point and lastly 4 stud weld manually done at four green points.

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Ma n u f a c t u r i n g P r o c e s s e s (MEM560)

4.1.6

OUTGOING

Finally, the complete assembly product then will be ready for delivery to their customer, to be
exact this product will be sent to PRODUA company to complete the assembly of Produa Alza. Below are
some of product which being manufactured by Autokeen for PRODUA.

Figure 9 - other product

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Ma n u f a c t u r i n g P r o c e s s e s (MEM560)

The standard operation procedure (S.O.P) for the assembly process is:

STEP 1

STEP 2

STEP 3

STEP 4

STEP 5

STEP 6

STEP 7

STEP 8

STEP 9

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Ma n u f a c t u r i n g P r o c e s s e s (MEM560)

STEP 10

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Ma n u f a c t u r i n g P r o c e s s e s (MEM560)

8.0

REFERENCES
1. http://www.thelibraryofmanufacturing.com/
2. http://en.wikipedia.org/wiki/List_of_manufacturing_processes
3. http://en.wikipedia.org/wiki/Outline_of_manufacturing
4. http://www.autokeen.com.my/about-us/

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Ma n u f a c t u r i n g P r o c e s s e s (MEM560)

9.0

APPENDICES

Figure 10 - Taking Photo with Autokeen manager

Figure 11 - Autokeen Building

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