Example Practical Report

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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 1

Transcript of Example Practical Report

Page 1: Example Practical Report

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.

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1.3 INTRA DETAILS

COMPANY NAME SONY EMCS (M) SDN BHDCOMPANY ADDRES Lot 5, Jalan Kemajuan,

Bangi Industrial Estate,43650 Bandar Baru Bangi,Selangor Darul Ehsan.

CONTACT NO.OFFICE: 03 - 8925 7587FAX: 03 - 59252649DEPARTMENT ATTACHED

Television Quality Reassurance (TV QR)

COMPANY SUPERVISOR

Mrs. Mazlinda Binti Abdul Majid

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.

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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.

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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.

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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

Location

Lot 5, Jalan Kemajuan,Bangi Industrial Estate,43650 Bandar Baru Bangi,Selangor.

Employee InvestmentRM 972 million (USD 256 million)

Products Manufactured

• Color Television• LCD Television• Projection Television• Tuner• Deflection Yoke• 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

which produced Sony’s branded Television. It was built in 7th October 1987, the first

operation and production of this factory begin from 1st 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.

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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

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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 DATEAPRIL 1988

(STM) KL TEC MERGE WITH (STM) PENANG TEC1 APRIL 2004

SONY NEW NAMESONY EMCS (M) SDN BHD

(SOEM)

MANAGING DIRECTOR (SOEM) 2004MR. T. KIKUCHI

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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)

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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.

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2.8 COMPANY ORGANIZATION CHART

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2.9

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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.

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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.

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Scope meter

Leakage current jig

Power amplifier EUT

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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

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Start

General Inspection

Mechanical Part Checking

Electrical Part Checking

Leakage Current

General Inspection

End

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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

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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.

Illustration 3.1: Energy Rating Label

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Australia & New Zealand

Malaysia

Japan

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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.

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3.9 SMELL TEST & OUTGAS EQUIPMENT LIST

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BLOWER

DUMMY SCREW

SCREW DRIVER

SMELL CHAMBER

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VACUUM BOX

RUBBEER COVER

SORBENT SILICA & COCONUT

MINI PUMP

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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.

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.

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SERIAL NO

PRODUCT NO

DESTINATION MODEL NAME

PP GREEN LABEL

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By using both hands, lift TV carefully from the carton to prevent defect from

occurring.

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.

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Lift Using Both Hands

SAME TAGGING NUMBER, FOR

EASY IDENTIFICATION

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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

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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.

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3.11 HOW TO SETTING TV

Select language.

Select area

Select type of use

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Select position

Start auto tuning

Tuning in progress

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Tuning finished, it shown number of program found

Set day and time

Setup complete

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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

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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

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EnterEnter  the details ofthe details of  suchsuch  a model,a model,  destination,destination,  serial no,serial no,  and date on theand date on the

paperpaper  provided.provided.  Attached theAttached the  paper on thepaper on the  Odor bag.Odor bag.

Fill at least four Odor bag with smell test sample. Give the sample to qualift

TVQR member for evaluation.

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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.

Setting the mini pump according to sorbent specification33

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Pump Setting

Take the sample using mini pump

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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.

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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.

Illustration 3.7: PP Stages Label

Illustration 3.8: MP Stages Label

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GREEN LABEL

BLUE LABEL

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There are also a model know as current model.

Illustration 3.9: Current Model Label

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NO LABEL

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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.

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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.

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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.

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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.

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CHAPTER 5

APPENDIX

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

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APPENDIX 2

Illustration 5.2: Proposed Area for General Expenses

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APPENDIX 3

Illustration 5.3: Set Information Form

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APPENDIX 4

Illustration 5.4: Jon Item Form

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