GMI Practical Report

Industrial In-Plant Training Report at Active Precision Sdn Bhd
1.0 INTRODUCTION
1.1 INDUSTRIAL IN-PLANT TRAINING
The Engineering discipline is practical in nature and mainly hinged on
experience. Hence, there is great need for any student aspiring to be a
professional engineer to have some form of work experience while studying at
school, in a reputable engineering firm related to his/her course of study.
Students Industrial In-Plant Training Scheme is in accordance with the higher

education policy of technical education to enable students to expose to the
working experience in industries and to enable them to be useful to their
employers practically and not theoretically alone.
The Students Industrial In-Plant Training Scheme gives students the
opportunity to gain some relevant experience before leaving the campus. The
experience gotten by the students during the In-Plant program would enable
them quickly fit into the industry upon graduation.
I had my Industrial In-Plant Training work experience at the Active

Precision Sdn Bhd (ACTIVE), a precision tooling company, and an indigenous
engineering firm. At ACTIVE, I have learnt the fundamentals of Mechanical
engineering; Computer Aided Design (CAD), Solid Works, and other relevant
software such as Computer Aided Manufacturing software (CAM),
Unigraphics, and AutoCAD (2D design software). My daily activities at
ACTIVE recorded in the GMI logbook.
1.2 AIM
The Students’ Industrial Training Scheme (In-Plant) is aim at giving students

the opportunity to have work experience and practically apply the theoretical
concepts learnt in the Institute. It is also aims at widening the mental and
creative horizon of the students.
Industrial In-Plant
Plant Training Report at Active Precision Sdn Bhd
2.0 IN PLANT WORKPLACE
Description of workplace:
NAME: ACTIVE PRECISION SDN BHD
ADDRESS: NO 2, JALAN LOMBONG EMAS 2, SEREMBAN LIGHT

INDUSTRIAL PARK, 70200, SEREMBAN,
Figure 1: Active Precision (HQ)

2.1 ACTIVE’s BRIFE HISTORY

Active Precision Sdn Bhd (ACTIVE) is Negeri Sembilan’s premier indigenous
engineering company. It was establish on the year 1993 and Commercial
business started in August 1995. ACTIVE fully owned by Mr Pathma, (MD of
Active) providing efficient and reliable engineering base for the entire
semiconductor, fabrication, and oil and gas industry.
Currently ACTIVE is serving for various multinational companies such

as Matsushita Group, Sony Group, Epson (M), Hitachi, Western Digital, Seiko
Instrument, Sun Power, Smart Modular, etc. We have enclosed details of the
company, which would provide you an overview of our company. We
confidently hope that our services would meet your requirements of any sort.
Our record of accomplishment on services and price has been very much of a
hand for the companies we serve.
The company also supplies the components in sub assembly condition.

In addition, an efficient team of talented technocrats strengthens us and a
well-equipped manufacturing plant outfitted with advanced technology
machinery imported from techno-rich countries like Japan, Germany, Korea
and USA.
Active’s motivation, drive, and target embedded in its vision and mission
statements thus:
Vision
“To be a world class Engineering Company.”
Figure 2: ACTIVE logo

Mission
“Provide world class engineering services in recognize Malaysia’s and
International companies.”
2.1.1 Quality Policy

“To satisfy and strive to exceed customer requirements and achieving highest
customer satisfaction in Cost, Quality and Time at all time with active
participation of all employees”.
Active Precision manufactures Precision Tooling- Tool & Die, Mould, and Jigs
& Fixture, to cater for a wide range of industrial applications.
ACTIVE’ intention is to deliver Precision Tooling and internationally through

meeting customer requirement and achieving highest customers’ satisfactions
in Cost, Quality, and Time at all times.
The management is committed to operate an effective quality management

system meeting the requirement of ISO 9001:2000 and ensure its
commitment at all levels of employees within its organization.
The quality objectives outlined are being monitor and review periodically to
indicate the actual performances of the Cost, Quality, and Time. Active will
continually strive to identify weak areas and improve its performance in order
to enhance their capabilities to consistently meet and exceed their customer’s
expectations.
Foreign engineers who have been train locally and abroad on live projects
and in all engineering disciplines manage ACTIVE. It is fully equipped to
provide its services in all areas of the precision tooling manufacturing.
Industrial In-Plant
2.1.2 Environmental Policy

“To be acquainted with applicable legal and other requirements, to minimize
the creation of waste and pollution with active participation of all employees”.
Active Precision manufactures Precision Tooling-

Tooling Tool & Die, Mould, and Jigs
& Fixture, to cater for
or a wide range of industrial applications.
ACTIVE’ Environmental Policy is to be a responsible corporate citizen in

protecting the environment. ACTIVE are committed to complying with
accepted environmental practices, including the commitment to meet or
exceed
ceed applicable legal and other requirements, to strive for continual
improvement in their environmental management system, and materials and
their people in order to reduce the environmental impacts associated with
their work.
ACTIVE pledges to implement and operate the ISO 14001:2004 EMS to

further enhance environmental performances. Their main objectives and
targets are,
Investigate the reduction of schedule wastes

Reduce, reuse or recycle generated scheduled wastes
Improve the storage efficiency of scheduled
scheduled wastes without
spills/leaks
This Environmental Policy will be communicated to all personals working for

or behalf of ACTIVE and available to the public.
Figure 3: ISO Certification

2.2 ACTIVE’s SERVICES
ACTIVE’s core services include the following:

• Manufacturing (Precision Component)
• Jigs & Fixtures
• Tools & Dies
• Moulds
• Project Management (Automation)
• Conceptual Engineering design
In order to create a conducive environment, ACTIVE has established one of

the most equipped engineering tool room in Seremban with the latest in
Engineering Equipments, Machines, Software, Project Management,
Administrative, Finance and Accounting software (UBS).
The company library is up-to-date with books on Engineering, Accounting,

Management, and all other disciplines relevant to its operations. It is also
equipped with Mechanical Engineering Literature, Drawings and
Documentation. It has Internet connection to a worldwide web for additional
engineering information and communication.
2.3 ACTIVE’s ORGANIZATIONAL STRUCTURE

Specific department undertakes all of ACTIVE’s activities, which can be
dividing into two major categories namely:
• Administration: -
This comprises of the non-technical departments.
• Production: -
Comprises of the technical departments.
Chart 1 shows a diagrammatic representation of the organisational structure

of ACTIVE.
MANAGING
DIRECTOR
LEGAL ADVISER
EXECUTIVE DIRECTOR, EXECUTIVE DIRECTOR,

(ADMINISTRATION) (PRODUCTION)
QA/QC
Department
Human
Sales Administration
Resource Engineering Manufacturing
Department Department
Department Department Department
CHART 1: ACTIVE’s ORGANIZATION CHART

MOT 091005 GERMAN MALAYSIAN INSTITUTE
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2.3.1 ACTIVE’s Departments

The various departments in ACTIVE and their functions with respect to project
execution are:
Non-Technical Departments:
• Finance and Accounts:
-Treasury management, billings, accounting and financial management.
• Administration and Personnel:

-Harnesses human and material resources and set out ways of utilizing
them in order to maximize profit. General administration and personnel
management.
• Business Development:
-Sourcing for business via bids or otherwise to ensure company growth.
• Public Affairs:
-Projecting and sustaining a favourable image for the company.
• Company secretariat/Legal Services:

-Providing legal insurance and board secretarial services.

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Technical Departments
• Engineering:
-It is the heart of ACTIVE. Preparation of engineering design and studies.
• Production:
-Organize/arrange staff development programs like on-the-job-training,
short-term courses and seminars, overseas rotational training etc, to
ensure that ACTIVE’s personnel are inform of technological advancement
in the industry. It ensures employee development.
• Manufacturing:
- Manufactures various precision parts, as per the customer’ drawing.
• Fabrication:
-Management of fabricating activities.
• Projects:
-Co-ordinates the engineering activities are undertake during any project
including arranging for site visits, liaison with the customers to inform them
about the progress of their projects. Manage of all capital projects.
• Project Controls:
-Project planning and scheduling, cost estimating, cost engineering and
information technology.
• Quality Assurance/ Control:

-Ensures compliance with company quality standards.

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2.4 ACTIVE’s EXPERIENCE

Since its inception, ACTIVE has executed over hundreds of projects of varying
magnitude and cost implications in past one year. Among those projects when I
was around are:
• Seiko Instrumentation, over 5 year’s Precision Tooling and Spare Parts

service.
• Scomi Rail, Fabricate Skid (radiator), exported parts.
• Western Digital, over 7 years Precision Tooling services
• Sun Power, Design, Manufacture, and Fabricate parts – which I met on

ground.
• Ceram Tech, jiggering machine overhaul (Automation) - which I met on

ground.
• Link Tech, Design, and Fabricate Generator - which I met on ground.
• Hitachi, 3T/4T Mould (Repair) - which I met on ground.
• Hitachi, Profan Mould (Maintenance) - which I met on ground.

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3.0 PROJECT EXECUTION IN ACTIVE

3.1 LOGBOOK
Every single task or activity has recorded in the logbook on daily basis. The
Supervisor on monthly basis were also reviewing the logbook where his
comments and technical advice per-training to the job done for the month given
to me for improvement for the followings’ tasks.
Below are the highlights of major achievement, which recorded in the logbook:
Service and repair the following moulds:

Profan (HITACHI)
3T/4T Mould (HITACHI)
Manufacture Precision Tooling Parts:

Lever HDS Bias
Mounting Bracket
‘L’ Jig
Wafer storage
Extruder Die
Ramp MDW Everest
Set Up Gauge Block
Singulation Plate
Ram Pin Guide
Indexing Finger
Bracket Plate
Toggle Plate
Flag
J Shoe
Etc.

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Manufacture Assembly Parts (Mass Production)

Locating Jig
PVC Elbow
Wafer Storage
Own Conceptual Designing

Power Generator
Slot Block
Bracket
Dispensing Hanger
Aluminum Manifold
Documentation
Site visiting reports
Create mould defection report
Amends Company Profile
Designing and Drawing Production

Sketching of the product
Design solid modeling.
Create assembly drawing.
CAD (SolidWorks software)
CAM programming (UNIGRAPHICS software)

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3.1.1 SELF-ASSESSMENT
Production Technology,
German Malaysian Institute.
Self-assessment of Industrial Training
1. Name of Trainee: Lukshman Rao

2. Name and address of Active Precision Sdn Bhd,
Company Seremban Light Industrial Park, Seremban.
3. Guide from Industry Mr Pathman
(With designation) Production Manager
4. Date of Commencement 03 January 2011
Of Industrial Training
5. Number of day is present 84 days out of 84 days.
6. I hereby declare that, I have learnt following skills during my Industrial
Training:
No. Description Weightage
(%)
1 Learning new Techniques – Software, Machines, Process etc. 20
2 Part designing, Assembly of parts components, Drawings 10
3 Mechanical designing, Assembly and Fabrication 20
4 Calibration, Testing, Servicing and Repairing 5
5 Installation / Commissioning 5
6 Research and Development 5
7 Quality Control, Inspection 10
8 Housekeeping, Maintenances 5
9 Site Visiting / Meeting with customers/end users 10
10 Purchase and Marketing 2
11 Documentation 5
12 Any other (Specify)- Transporter/Dispatcher 3
Total 100
Date: Signature of Student

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3.2 PROJECT INITILIZATION
ACTIVE’s business starts in the Business Development department when it

receives invitations from prospective clients to submit competitive
bids/quotations for executing projects. Relevant departments meet to decide
whether the decision is worthwhile. A project manager is appointing to
coordinate the preparation of the bid. This usually involves most of the
departments. Finally, the Business Development department submits the
proposal and follows it up.
If the bid is successful, ACTIVE management appoints from various

departments a Project Manager and other personnel that will form the project
team.
The Project Manager maintains a harmonious relationship with the client and
ensures that his personnel have the right facilities and a conductive working
environment to execute the project.
The Finance and Accounts department prepares invoices and collects

payments from clients. This helps to maintain a positive cash flow and to
ensure that funds are available for the payment of wages and other corporate
expenses.
A typical project team usually comprises mainly of personnel from the

Production department.

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4.0 THE PRODUCTION DEPARTMENT
4.1 INTRODUCTION
Usually, a typical project begins in the process group with the conceptual or
basic design. The process group develops the initial part drawings, evaluates
all the options, and proposes the best alternative for the manufacturing. Other
disciplines will then work on what the process group has put down.
4.2 PRODUCTION DEPARTMENT

The Production department is the ‘engine room’ of ACTIVE’s operations. The
department is directly involved in the execution of jobs and on whose
shoulders the responsibility of meeting client’s specification, quality, work
procedure, standards and schedule rests.
The department is dividing into discipline groups. A manager, who reports to

the Executive Director Operations, is Head of the Engineering Department. A
team of Engineers of the various discipline groups fulfils the role of the
department. An Engineer who is more knowledgeable in the activities of the
group leads each of the discipline groups.
During the training, I was attached to the Manufacturing and Engineering

discipline group which is under the Production department.
Figure 2 shows the organizational structure for the Production department.
4.3 ROLES OF THE PRODUCTION DEPARTMENT

On any project, the Production department is concerned with the following:
To cultivates the manufacturing quality.

To ensures that the manufacturing sector is equipped with maximum
facilities.
To develop manufacturing sector that is reliable, economical and

operationally flexible.

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PRODUCTION
MANAGER
ASSISTANCE
MANAGER
LEAD, LEAD, LEAD,

MANUFACTURING ENGINEERING ELECRICAL
MANUFACTURING ENGINEERING ELECTRICAL

GROUP GROUP GROUP
CHART 2: ORGANIZATIONAL STRUCTURE OF THE PRODUCTION

DEPARTMENT

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4.4 MANUFACTURING GROUP ACTIVITIES

To achieve the above objectives, the manufacturing group usually carries out the following
activities:
Develop designing criteria.
Formulate complete parts and assembly drawings.
Prepare material requisition (MR) and Bill of Quantities (BOQ) for assembly drawing
Create a process plan for each part.
Analyse machine/equipment needed.
Separate the drawings based on process involved
Carry on with manufacturing processes.
Send to QA/QC department.
4.5 MANUFACTURING GROUP DELIVERABLES

Deliverables are documents produced by a group with respect to the scope of the project. The
deliverables produced by the manufacturing group are -
Conceptual Designing
Assembly drawings
- Exploded
- Detailed
- Notes
Material Requisition (MR)
Bill of Material (BOM)
Drawing and part numbering
Detail Dimension Drawing
- Complete dimensions
- Projection angle (top, front, side)
- Isometric view
- Detail drawings
- Tolerances specification

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COMPUTER SOFTWARES used by the Manufacturing group are;

SolidWorks (Designing)
CATIA (Manufacturing)
Unigraphics (Manufacturing)
MasterCAM (Manufacturing)
AutoCAD (2D Drawings)
Microsoft Excel (Documentation)
Microsoft Word (Documentation)

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5.0 SKILLS & PRACTICES ACQUIRED
5.1 Knowledge Acquired
From the day one of my In Plant Training, I were attach to the Production
Department, which is relates to my core course. I was attach in both manufacturing and
engineering departments, which my mainly my tack covers all from conceptual
designing until manufacturing the parts/products.
I was in ACTIVE with my colleague, which is also from GMI. After two weeks of
performances, our Production Manager, Mr Pathma, instructed us to be an assistance
supervisor/ leader trainee in Manufacturing and Designing sector respectively. Our
tasks was unique, because we were an assistance at the same time we also design,
manufacture, and lead a team to accomplish a task on site.
Several tasks accomplished by me personally and of course some with the
advice of my supervisor. Those are involved in mould repair and maintenance,
manufacturing precision parts, designing, on site modification/assemblies, working in
clean room in Western Digital and Sun Power and involved in reports/documentation.
The major activities /task, which I lead or carry out personally in ACTIVE, are as
following,

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Repair and Service Moulds
-Split the mould
• Figure 4: Mould Splitting
a. Safely lift the mould by crane, 4 lifting points normally. Stand it on the
ground cushioned by wooden or rubber.
b. The mould must be place on two rails on a clean table with sufficient
space. Tools used must be in good condition and should include Allen
wrenches, aluminium pry bars, rubber mallet, duct tape, and some
containers.

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c. Separate mould at parting line carefully and look for any visible damage. If
mould is damage, report it at once. Check for rust in core and cavity and
report it at once if found.
d. Have containers to put all the parts in and identify it with the proper job
number.
e. Check for core pins in Ejector Housing (at the bottom clamp plate) and
remove the core pins first.
f. Remove all necessary screws in the Ejector Housing and remove it.
g. Remove screws from the Ejector Plate and remove it.
h. Check if all pins are marked, if not mark as necessary.
i. Remove all pins and parts from Ejector Housing. Protect all fragile parts
and critical areas with duct tape.
j. Remove all water line jiffy-plugs
k. Remove all slides assemblies and protect all critical areas with tape or
carefully store in container.
l. Remove the Sprue bushing, hot sprue, or any hot runner system.
m. Remove all screws from cavity and core inserts and install two or four
longer screws in cavity and core. Then knock out cavity and core inserts
from mould base by hitting screws with a rubber, aluminium, or copper
mallet. BE CAREFUL NOT to knock insert out onto the bench or floor and
damage it.
n. Once the primary inserts removed, remove all sub-inserts, gate inserts,
core pins, etc. and protect all critical edges with tape or carefully store in
container.
o. Carefully clean all details with a clean, mild solvent and clean towels being
careful NOT to damage sharp edges, parting surfaces, shutoffs, or the
cavity finish.
p. Finally, store all inserts in such a way that the moulding surfaces protected
for the next working procedure and cannot be accidentally damage. Clean
and grease others to avoid rust and put in safe position.
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Remove clogged material in cavity plate

a) Remove insert plate from cavity plate
b) Make sure remove o-ring before heat cavity plate
c) Heat cavity plate using burner approximately 10 minute
d) Gentle knock the plastic material using pin (smaller then runner diameter) and
mallet
e) Be careful NOT to damage, runner area by accidently knock cavity area.
• Figure 5: Material clogged and removed

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Industrial In-Plant
Increase width of the runner

a) Rub cavity plate with polishing stone to remove burr and clean the cavity
plate using clean cloth
b) Clamp cavity plate in the CNC machine table using clamp kit
c) Mill runner wall per side 0.25mm using 5 degree angle cutter, depth of the
runner maintain 5mm
d) Careful remove cavity plate from CNC machine, for next procedure
e) Polish runner area after machining using oil stone
f) Carefully clean cavity plate with a clean, mild solvent and clean cloth
• Figure 6: Machining (modification)

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Repair mould-flashing area

a) Indentify core insert depression area
b) Weld depression area, approximately 0.5 mm thickness
c) Rub cavity plate with polishing stone to remove burr and clean the cavity
plate using clean cloth
d) Clamp core insert plate in the grinding machine, grind flat to the surface
e) Remove core insert from grinding table for next procedure
f) Polish cavity finish area using oil stone
g) Carefully clean cavity plate with a clean, mild solvent and clean cloth
• Figure 7: Welding and Polish critical area

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Mould Maintenance
a) Check ejector pins, guide pin ejection fully forward position. Ensure they
are not loose and free from galling on the rods.
b) Blow off water remained in the waterlines under high air pressure
c) Clean the mould surface with proper cleaning agent or blow the mould
with high air pressure
d) Grease regularly all un-self lubrication parts like guide bushes, angle
location plates or wear plates.
e) Spray antirust agent inside mould.
f) Check all identification plates whether they are legible, in position or not
g) Place the mould in planned location with good protection on all extending
parts.
Figure 8: Mould Maintenances

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Mould assembly
a) Procedure of assembly reverses that of disassembly of the mould.
b) Grease all un-self lubrication parts like guide bushes, Guide pins or wear
plates
c) Spray antirust agent inside mould surface.
• Figure 9: Completed and assembled mould

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Manufacturing Precision Parts
• Figure 10: Compares’ squaring and completed Part
Part Name: Ramp, WDM, Everest-10D

Drawing No: 2963-703253-000-01P (Refer Appendix 1)
Material: 316 SST
Company: Western Digital (Malaysia)
Process Plan
Squaring
Grinding included w/cut allowance
Drilling
W/cut process
Parting • Figure 11: Hand Polishing
Hole and slot w/cut

Profile cutting with polishing allowance
1st Polishing (hand polishing)
Electro polishing
1st Inspection
2nd Polishing (gloss required areas)
Final Inspection
• Figure 12: Part Inspection

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• Figure 13: Set Up Gage Blocks

• Figure 14: Part before W/Cut Process
Part Name: Set-Up Gage Block W/Pivot and W/O Pivot

Drawing No: 09-80743-00 (Refer Appendix 2-4)
Material: SST 440, 54-60 RC
Process Plan
Squaring
Drilling
Hardening (54-60 RC)
• Figure 15: Work Piece Setting
Grinding
W/cut process
Hole, Pocket and Slot w/cut
Profile cutting with polishing allowance
Polishing (hand polishing)
Inspection
• Figure 16: W/Cut Process

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Industrial In-Plant
• Figure 17: Toggle (J-Shoe)

Shoe)
Part Name: Toggle for R16 M/C

Drawing No: R648-11710
11710-LE-3 (Refer Appendix 5)
Material: DF 2/SNC 22 (HRC 53)
Company: Seiko Instrument Technologies (Singapore)
Process Plan
Squaring with grinding allowance
Drilling
Hardening (HRC 53)
W/cut process
Profile cutting
Polishing (Sandpaper Machine)
Grinding
Inspection

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• Figure 18: Indexing Plate Finger
Part Name: Indexing Plate Finger for PC4 M/C

Drawing No: R648-2241-LE-3
Material: DF 2/SNC 22 (HRC 60)
Company: Seiko Instrument Technologies (Singapore)
Process Plan
Squaring with grinding allowance
Drilling
Tapping (M5)
Hardening (HRC 60)
W/cut Process
Profile cutting
Polishing (Sandpaper Machine) • Figure 19: Completed Part
Grinding
Inspection

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• Figure 20: Complete assembled ‘L’ Jig
Part Name: ‘L’-Jig for Glass Storage

Drawing No: APSB/139/0311/00 (Refer Appendix 6)
Material: Derlin / POM
Company: AUO Sun Power (Malaysia)
Process Plan
Raw Material Squaring • Figure 21: Part Modelling
CNC Profile Milling

Steps, U/Cuts
Radius
Conventional Milling
Groove
Radius
Drilling • Figure 22: During Machining
Deburring
Inspection
• Figure 23: Complete Machined Part

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• Figure 24: Sample ‘Extruder Die’

• Figure 25: Part Simulation
Part Name: Extruder Die (806/7.5)

Material: Aluminium
Company: Hoest Ceram Tec (Malaysia)
Process Plan
Material Cutting
Lathe Machine Process
CNC Milling
• Figure 26: Lathe Machine Process
Boring
Radius Profile Cutting
Drilling
C/boring
Polishing
Chamfering/Deburring
Inspection
• Figure 27: CNC Milling Process

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Manufacturing Assembly Parts (Mass Production)
• Figure 29: Squaring Parts

• Figure 28: Locating Jig assembly stages
Part Name: Locating Jig

Drawing No: APSB/XXX/1011/00 (Refer Appendix?)
Material: Polypropylene & Derlin
• Figure 30: Tapping Process

General Process Plan
Material Cutting
Squaring Process
CNC Milling
Slotting
Drilling
C/boring
Conventional Milling (Angle) • Figure 31: Washing Process
Washing/Cleaning Process
Assembly Process
Inspection using actual part
• Figure 32: Assembly Process

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• Figure 33: Wafer Storage
Part Name: Wafer Storage Gen 4ASSY

Drawing No: SC-SPC-WT1-490-00 (Refer Appendix 8-11)
Material: T6 Aluminium

Material Cutting
Squaring Process
CNC Milling
Slotting
Drilling
C/boring
Profile Milling
W/Cut Process (Slots)
Anodizing (Coating)
Pin Grinding
Assembly Process
Brazing (Alz Welding)

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• Figure 34: Pneumatic Vacuum

• Figure 35: Pneumatic Tubing
Part Name: Pneumatic Vacuum for
Viking and Mars
Drawing No: APSB/009/0609 (refer appendix 12)
Material: T6 Aluminium, Pomulux SD

Modelling
Test cut (different material) • Figure 36: Mars Suction Part and Jig
Material Cutting
Squaring Process
CNC Milling Process
Slotting
Drilling
C/boring
Profile Milling
• Figure 37: Viking Suction Part and Jig
Alz Anodizing (Coating)
Assembly Process

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Conceptual Designing
• Figure 38: Grease Dispensing Rail • Figure 39: Modification Modelling
Part Name: Rail Grease Dispensing Hanger

Material: Brass, Stainless Steel, PVC
Tasks
To modify the original ‘grease dispensing rail’ by adding two pressure grease
tank.
Reduce the width of the rail holder/clamp.
Reduce the total weight of the hanger.
Change the current PVC clip size to smaller size.

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• Figure 40: Power Generator
Part Name: Power Generator and Manifold

Drawing No: APSB/123/0111/00 (Refer Appendix 14&15)
Material: N/A
Company: Link Tech (Malaysia)
Tasks
To create housing for new invented of 2 Phase Power Generator.
Consist of two units of batteries, two output power switches, circuit breaker,
Voltage reader, Ampere reader, vacuum suction fan.
Top cover, label engraving.
Foam sprays coating (blue).
Urethane rubber base protector

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Machine Maintanances
• Figure 41: SODICK Wire Cut Machine • Figure 42: Before Cleaning Started
Machine Name: CNC Wire Cut Machine

Model Name: SODICK AQ327L
Duration: Approx. 5-6 Hours
Task Carried
Clean the machine exterior and filters
Clean the conductivity piece (top & bottom)
Deionizer liquid maintenance
Clean upper & lower wire guide
Figure 43: After Cleaning Process Completed
Clean all the metal dust in the machine
Add deionizer resin
Set wire straightness
• Figure 44: Conductivity piece

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• Figure 45: Soaked in K-12 acid
Figure 46: CNC Vertical Milling Machine
• Figure 47: Air pressure control unit

Machine Name: CNC Vertical Milling Machine
Model Name: Quick Tech VMC 1070
Duration: Approx. 3 Hours
Task Carried
Clean the machine exterior and filters
Clean machine’s scrap tray (inside machine)
Clean the scrap drain
Figure 48: Hydraulic oil tank
Wash machine interior (using coolant)
Drain the coolant sludge and add new coolant
Release tool changer pressure
Add hydraulic/slide way oil
Clean the filter and dust in machine power box.
• Figure 49: Machine Control Box

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Site Work
• Figure 50: Machine relocation • Figure 51: On site Work Place
Machine: Twin Jiggering Machine

Company Name: Hoest Ceram Tech
Duration: 3 Weeks
Task Carried
Relocate the machine to Site Work Place
Disassemble the machine components (note all the parts)
Clean the machine parts
Modification takes place
Fabrication process
Assembly process
Test run and construct an report
Relocate the machine to its original place
Final test run
• Figure 52: Moving the Machine

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• Figure 53: Jiggering Machine
Machine: Jiggering Machine

Company Name: Hoest Ceram Tech
Duration: 2 Months
• Figure 54: At customers’ Plant
Task Carried
Clean the machine exterior and interior
Disassemble the machine components (note all the parts)
Clean the machine parts using kerosene
Replace the cams
Replace the guide shaft
Fabrication process
Assembly process
Welding process
Test run the machine
Oven coating the machine body
Cover assembly process
Final test run • Figure 55: After complete (In-House)

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House-Kepping
• Figure 56: Production floor cleaning • Figure 57: Machine Cleaning
Task Carried
Done by daily basis
15 minutes Before and after work
Noted duties carried out
Clear the rubbish bin once filled
Vacuum the dust around the production floor
Clean air-cond filter
Update notice whiteboard

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RECOMMENDATIONS
It is important that every level of worker in the company be able to do their job fully.
Delays due to numerous consulting of higher members of the company reduce the
effect of the workforce hired. Unskilled labourers been hired by the company make
errors. This also produces time delays and costly mistakes, which would require the
skills of a higher ranked employee of the company. This causes a chain of time
consuming that ripples through the workforce to a certain extent. The employees follow
not all safety regulations. This leads to risk of mishaps and serious injuries to
employees.
CONCLUSION
The Industrial In-Plant Training has positively contributed to my training as a future
Mechanical Engineer. At the In-Plant workplace (i.e. ACTIVE), I was able to reconcile
theoretical principles learnt in school with real Mechanical engineering design practice. I
also learnt various software applications relating to my discipline such as AutoCAD,
Solid Works, Unigraphics, Master Cam, CATIA, Microsoft EXCEL, Microsoft Word, etc.
Furthermore, I received extensive training on conceptual design fundamentals that
included from part design until assembly design. IN-Plant also gave me the opportunity
to learn about good work ethics, good interpersonal and communication skills.
The time spent on all the sites increased my knowledge of the industry in practical
sense and thus gives me the confidence to be certain of the future growth of my skills
and knowledge of the industry.

44
REFERENCES
Active Precision Sdn Bhd, Company Profile.

Mr.Rahman, Institute based supervisor, German Malaysian Institute.
Standard Industrial Report Format, GMI library.
Chevron Corporation Training Manual (1996), Vol 1 & 2.

45

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Industrial In-Plant Training Report at Active Precision Sdn Bhd

Students Industrial In-Plant Training Scheme is in accordance with the higher

I had my Industrial In-Plant Training work experience at the Active

The Students’ Industrial Training Scheme (In-Plant) is aim at giving students

2.0 IN PLANT WORKPLACE

NAME: ACTIVE PRECISION SDN BHD

ADDRESS: NO 2, JALAN LOMBONG EMAS 2, SEREMBAN LIGHT

Figure 1: Active Precision (HQ)

2.1 ACTIVE’s BRIFE HISTORY

Currently ACTIVE is serving for various multinational companies such

The company also supplies the components in sub assembly condition.

Figure 2: ACTIVE logo

2.1.1 Quality Policy

ACTIVE’ intention is to deliver Precision Tooling and internationally through

The management is committed to operate an effective quality management

2.1.2 Environmental Policy

Active Precision manufactures Precision Tooling-

ACTIVE’ Environmental Policy is to be a responsible corporate citizen in

ACTIVE pledges to implement and operate the ISO 14001:2004 EMS to

Investigate the reduction of schedule wastes

This Environmental Policy will be communicated to all personals working for

Figure 3: ISO Certification

2.2 ACTIVE’s SERVICES

ACTIVE’s core services include the following:

In order to create a conducive environment, ACTIVE has established one of

The company library is up-to-date with books on Engineering, Accounting,

2.3 ACTIVE’s ORGANIZATIONAL STRUCTURE

Chart 1 shows a diagrammatic representation of the organisational structure

EXECUTIVE DIRECTOR, EXECUTIVE DIRECTOR,

CHART 1: ACTIVE’s ORGANIZATION CHART

2.3.1 ACTIVE’s Departments

• Administration and Personnel:

• Company secretariat/Legal Services:

MOT 091005 GERMAN MALAYSIAN INSTITUTE

• Quality Assurance/ Control:

MOT 091005 GERMAN MALAYSIAN INSTITUTE

2.4 ACTIVE’s EXPERIENCE

• Seiko Instrumentation, over 5 year’s Precision Tooling and Spare Parts

• Scomi Rail, Fabricate Skid (radiator), exported parts.

• Western Digital, over 7 years Precision Tooling services

• Sun Power, Design, Manufacture, and Fabricate parts – which I met on

• Ceram Tech, jiggering machine overhaul (Automation) - which I met on

• Link Tech, Design, and Fabricate Generator - which I met on ground.

• Hitachi, 3T/4T Mould (Repair) - which I met on ground.

• Hitachi, Profan Mould (Maintenance) - which I met on ground.

MOT 091005 GERMAN MALAYSIAN INSTITUTE

3.0 PROJECT EXECUTION IN ACTIVE

Service and repair the following moulds:

Manufacture Precision Tooling Parts:

MOT 091005 GERMAN MALAYSIAN INSTITUTE

Manufacture Assembly Parts (Mass Production)

Own Conceptual Designing

Designing and Drawing Production

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1. Name of Trainee: Lukshman Rao

Date: Signature of Student

3.2 PROJECT INITILIZATION

ACTIVE’s business starts in the Business Development department when it

If the bid is successful, ACTIVE management appoints from various

The Finance and Accounts department prepares invoices and collects

A typical project team usually comprises mainly of personnel from the

MOT 091005 GERMAN MALAYSIAN INSTITUTE

4.0 THE PRODUCTION DEPARTMENT

4.2 PRODUCTION DEPARTMENT