1.3.7 Kaizen 20
2.0 INDUSTRIAL INTERNSHIP PROJECTS AND MAIN ACTIVITIES 21
2.1 JIG FOR CAMERA MODULE INSPECTION 21
2.1.1 Description 21
2.1.2 Preparation of Jig 23
2.1.3 Schematics of Jig 24
2.1.4 Procedure of Inspection 25
2.1.5 Result 26
2.2 NEW PART MANAGEMET INVESTIGATION
PROCESS FLOW 27
2.2.1 Description 27
2.2.2 Procedure During Online (PP stage and MP stage) 28
3.0 LESSON LEARNED AND EXPERIENCED GAINED 30
3.1 LEADERSHIP, TEAM WORK AND INDIVIDUAL
ACTIVITIES 30
3.2 BUSINESS VALUES, ETHICS AND MANAGEMENT
SKILLS 31
3.3 SAFETY TRAINING AND VALUE OF PRACTICAL
EXPERINCE 31
3.4 PROBLEMS OR CHALLENGES FACED AND SOLUTION
TO OVERCOME THEM 32
3.5 PQA SCOPE OF WORK 32
4.0 DISCUSSION AND RECOMMENDATION 33
4.1 STUDENT INDUSTRIAL INTERNSHIP UNIT (SIIU) 34
4.2 HOST COMPANY – SONY EMCS 35
5.0 CONCLUSION 36
6.0 REFERENCES 37
APPENDICES 38
LIST OF FIGURES
- Figure 1: Masura Ibuka and Akio Morita, the founder of Sony
- Figure 2: Sony EMCS (Malaysia) Sdn. Bhd. KL Tec – South plant
- Figure 3: Sony Evolutions From 1986 until 2004
- Figure 4: PQA organization chart
- Figure 5: Electronic display
- Figure 6: LCD TV Operating Layers
- Figure 7: New Part Management Investigation Process Flow.
- Figure 8: New model stages.
- Figure 9: 5 series name of FY’10 New Model
- Figure 10 : Model name for FY ’10 New Model.
- Figure 11: Camera Module.
- Figure 12 :USB cable.
- Figure 13: Wire harness.
- Figure 14: Schematics drawing.
- Figure 15: Jig connect together with camera module.
- Figure 16: Connect jig to USB drive.
- Figure 17: Open My Computer>USB device.
- Figure 18: Picture from Camera Module.
- Figure 19: Investigation skills.
LIST OF TABLES
- Table 1 : Cadmium and Plumbum maximum level
- Table 2 : Duty of department during online
1.0 INTRODUCTION
1.1 BRIEF DESCRIPTION OF HOST COMPANY
1.1.1 Sony Corporation
Sony Corporation (ソニー株式会社 Sonī Kabushiki kaisha) is a multinational corporation headquarters in Minota, Tokyo, Japan. It was founded in May 1946 by Mr. Masura Ibuka and Mr. Akio Morita.
Sony Corporation is the electronics business unit and the parent company of the Sony Group, which is engaged in business through its five operating segments - 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 Corporation was formerly known as Tokyo Tsushin Kogyo (Tokyo Telecommunications Engineering). Later, its name was changed to SONY, which is a combination of two Latin words ‘sonus’ and ‘sunny’. In Latin, ‘sonus’ is the root word for sound and sonic, and ‘sunny’ means little son.
The name SONY is used to represent a very small group of young people who have the energy and passion towards unlimited creation. It symbolizes the spirit and the motivation of Sony to stay committed to customers and to enhance its reputation in taking its innovations into the future of digital technology.
Figure 1: Masura Ibuka and Akio Morita, the founder of Sony
1.1.2 Sony EMCS (M) Sdn. Bhd.
Sony TV/Video (M) Sdn. Bhd. was formed in 1987 and Sony Electronic (M) Sdn. Bhd. was formed in 1989. The two companies merged to form Sony Technology (M) Sdn. Bhd. in 1999. In 2004, Sony EMCS (Engineering, Manufacturing and Customer Service) (M) Sdn. Bhd. was formed with the consolidation of Sony Technology (M) Sdn. Bhd. and Sony PG Technology (M) Sdn. Bhd.
Sony EMCS (Malaysia) Sdn. Bhd. consists of two manufacturing entities, one in Bangi, Selangor (KL Tec) and the other in Prai, Penang (PG Tec). Majoring in electrical and electronic products engineering, manufacturing and customer services, Sony EMCS Malaysia is a multinational company and the top five companies in Malaysia in terms of sales volume.
SOEM comprises of four manufacturing and business sectors; Home Video manufacturing, Data Storage manufacturing, Display manufacturing and the Television for General Area business sector. Among products produced by Sony
EMCS Malaysia includes LCD-TV and DVD players. These products were mostly exported to countries such as Australia, Hong Kong, New Zealand, India, Singapore and many more.
The author was placed in Sony EMCS Malaysia (KL Tec). KL Tec consists of North Plant and South Plant. The manufacturing plant produces DVD players, LCD-TV and other key components such as boards, tuner and etc.
Figure 2: Sony EMCS (Malaysia) Sdn. Bhd. KL Tec – South plant
Figure 3: Sony Evolutions From 1986 until 2004
1.1.3 Parts Quality Assurance Department
The author was assigned to Parts Quality Assurance (PQA) Department. Basically, PQA roles are to ensure all the part are in a good condition and reliable before it is used in the production activity. In PQA department, there are three main groups which are New Part Management (NPM), Incoming Quality Assurance (IQA) and Supplier Management(SM). I was attached to NPM group.
In NPM group, I must confirmed all the new parts specifically electrical parts used in a new model introduction and make sure all the parts is reliable to use in production activity. It is very important to deliver good quality part before it had been used in production line.
Furthermore, SONY emphasized in terms of quality and safety. All works must strictly follow Standard Operation of Procedure (SOP). Finally, all departments are related and hardly work as a strong unit to produce good quality product.
Figure 4 : PQA organization chart.
- OBJECTIVE OF INDUSTRIAL TRAINING
The objective of the establishment of University Technology Petronas (UTP) is to produce well-rounded graduates who posses with technical competence, lifetime learning capacity, critical thinking, communication and behavioral skills, business acumen, practical aptitude and solution synthesis ability. The main objectives of industrial internship are:
-
To integrate theory with practice.
Theory learned must be practice in a real life application. Thru industrial internship program, student will have the opportunity to correlate theory learned at university with the practical application in the industry.
- To introduce students to work culture and industrial practices.
Internship program will expose students to the work culture and the industrial practices of their field choices.
- To acquire student’s skills in communication, management and team-work
Students will develop their communication skills and become more independent as being practiced by working community and able to manage the task that has been given.
- To give opportunity to student to work with industrial practitioners
Student will work and communicate with the practitioners from different position such as managers, engineers, technicians, vendor and etc.
- To expose students to potential employers
Students will have an opportunity to create good acquaintances with the individuals and organizations involved in the industry, which hopefully will be useful for future purposes.
- To acquaint the UTP students with industry and its programs
Students will aware on various industries related to their field of studies. In the same time, it also enhances the student’s work ethics thru the ethics practiced by industrial practitioners.
- To implement Health Safety and Environment (HSE) practices at workplace
Student will aware with the safety at workplace and be prepare if any incident occur at workplace.
- SCOPE OF WORK
This section will explain about the task that has been assigned to the author during 8 months of her service in SOEM. The tasks undertaken during industrial internship are as follows:
1.3.1 Generate new part list from the system
New part list is the report of all new part used in every new model. It is essential because we must make sure all the parts are in good quality and will not bring harm to the finish goods. The system used is Oracle and Qoo system. Furthermore the author must make sure Online Judgement Meeting(OLJ) and Shipping Confirmation Meeting(SCM) report is done before the meeting.
1.3.2 Introduction to TFT LCD
The images in any electronic display are made up of millions of tiny pixels. Pixels in a color display are in turn made up of sub-pixels (red, green, and blue). LCD, or liquid crystal display, is a commonly used electronic display found in a variety of electronic devices, including cell phones, laptop computers, computer, monitors, LCD TVs, calculators and digital watches.
Figure 5 : Electronic display.
A display (LCD) is an realized as a thin, flat made up of any number of color or arrayed in front of a or . It is often utilized in -powered devices because it uses very small amounts of .
Thin Film Transistor (TFT) LCD has a sandwich-like structure with liquid crystal filled between two glass plates. TFT Glass has as many TFTs as the number of pixels displayed, while a Color Filter Glass has color filter which generates color. Liquid crystals move according to the difference in voltage between the Color Filter Glass and the TFT Glass. The amount of light supplied by Back Light is determined by the amount of movement of the liquid crystals in such a way as to generate color.
Figure 6 : LCD TV Operating Layers.
- New Part Management Investigation Process Flow
There are number of processes involved before assembling the LCD set. A brief description of the processes from the input is shown in the illustration below:-
Figure 7 : New Part Management Investigation Process Flow.
This task will be further discuss in Section 2.2.
1.3.4 Jig for Camera Module Inspection
Along the internship period, the author has been given a responsibility to do a project involving inspection parts. So, author successfully build a jig that used to inspect camera module used in Tango model. The task will be discussing further in Section 2.1.
1.3.5 XRF
The author has been assigned to do XRF for each new part used. XRF is basically is X-Ray Fluorescent test. It is vital because all parts that been supplied to SOEM must not exceed the maximum level of lead (Pb) and cadmium (Cd). SOEM has huge responsibility to produce an environmental friendly product.
Table 1 : Cadmium and Plumbum maximum level
1.3.6 New Model Stages
In every new model, they have to undergo several steps before it can be finally ship out to destination given. Below illustrations are the stages involved ;
Figure 8 : New model stages.
Auto Mount : Mount chip part on the board
Hand Mount : Mount part such as phono jack, and jack on the board
PVT : Also known as Pre-Verification Trial to troubleshoot the model before running in production.
PP : Also known as Pre-Production. Only 10 set for each model and during this stages all problem regarding the model will be pick up and investigate.
MP : Also known as Mass-Production. During this stages, production will produce almost 100 set of the model.
Ship Out : After SCM, set will be deliver to each destination and become current model.
1.3.7 Kaizen (改善)
Kaizen is a Japanese word which means making changes for the better on a continual, never ending basis. ‘Kai’ means change while ‘Zen’ means good.
The author has been actively involved in KAIZEN activities since the first week reporting in PQA Department. While joining this activity, the author has learnt the art of realizing and reducing MURA (inconsistencies) and MUDA (waste) which are the essential parts in KAIZEN practices to benefit the company.
In most cases ideas for KAIZEN are not for major changes. Kaizen is based on making little changes on a regular basis-always improving productivity, safety and effectiveness, and reducing waste. Attached in Appendix is a sample of KAIZEN reports that the author was previously involved with
2.0 INDUSTRIAL INTERNSHIP PROJECT AND MAIN ACTIVITIES
2.1 JIG FOR CAMERA MODULE INSPECTION
2.1.1 Description
For FY’10 New Model, there have three main chassis; AZ1-A, AZ1-L and AZ1-H. Basically AZ1-A is design by TVOPA (TV Operation of Pan Asia) SOEM which is currently state in North Plant. AZ1-L and AZ1-H was design by designer SONY from Inazawa Plant, Japan. Every model states the model name, series name with the segment name such as for model name CYMBAL, the segment no is 3a-2 and the series name is EX. Every chassis have their own model name. Based on designer, the entire series name is followed by their features and their product key of rationality factor and willingness to pay a premium.
Figure 9 : 5 series name of FY’10 New Model
Figure 10 : Model name for FY ’10 New Model.
So, camera module is one of the part that been used in Tango Model which are PIANO. Below is the illustration of camera module ;
Figure 11 : Camera Module.
The purpose of having the camera module is to control the sharpness and brightness of the LCD set depending on the position of the viewer.
2.1.2 Preparation of Jig
The author has responsible to prepare the jig for inspection of the camera, thus the author must identify what are the easiest way in making the jig. So, the jig was made out from
- USB cable
- Harness that connected to camera module
Figure 12 : USB cable.
Figure 13 : Wire harness.
2.1.3 Schematics of Jig
Below is the illustration of the schematics design ;
Figure 14 : Schematics drawing.
Schematics shown are the connection between the USB cable and wire harness in order to inspect camera module.
2.1.4 Procedure Of Inspection
- After assemble the USB cable with the wire harness, connect the jig with camera module.
Figure 15 : Jig connect together with camera module.
- Connect them together and plug-it into USB drive at PC or Laptop.
Figure 16 : Connect jig to USB drive.
- Open My Computer > USB device.
Figure 17 : Open My Computer>USB device.
- Pop-up window will appear and picture from camera module will appear. Inspect by moving the position of camera module and the sharpness and brightness of picture show.
Figure 18 : Picture from Camera Module.
2.1.5 Result
From the above inspection, the author basically finished up 200 camera module and result is OK for that 200 camera module.
2.2 NEW PART MANAGEMET INVESTIGATION PROCESS FLOW
2.2.1 Description
For each new model, problems may occurred during incoming or during production activity. So, as stated previously in section 1.3.1.2, below are the brief description in each process flow ;
Generate new part list from system
As explain previously, first we must identify all the new parts in the new upcoming model. This is essential before we can proceed to the next step of the process flow.
Identify critical part and inspection
From the new part list, we can identify the critical part. Such critical parts are power cord, transformer, ac adaptor, relay, power board and power switch. For the critical parts, the inspection must be done 100% because it can bring harm if malfunction happen. For others part, inspection is done almost 70%.
Monitor online model
Then, we must monitor the online model during Pre-Production(PP) Activity. It is to ensure the production activity happen smoothly without any problem happen due to the part used.
Investigate the pick up problem
During the PP activity, if there are any pick up problem, PQA must investigate if it is due to parts problem. Part must be inspect and root cause must be determined to find whether it is a supplier problem or others. If happen is due to supplier problem, PQA must be the one who take the responsibility.
Follow up countermeasure and issue BNP
After investigate the problem and inform supplier, PQA must ask supplier to follow-up countermeasure in order to prevent the same problem happen during Mass-Production (MP). Then after received countermeasure, BNP will be issued.
2.2.2 Procedure During Online (PP stages and MP stages)
All departments that related to the new model will join the introduction of the model to confirm the actual process against operation manual (SOP). All department involve have their own duty.
Table 2 : Duty of department during online
During PP stages online, any problem will highlight and will be feedback to responsible for counter measure for MP stages. Details of author’s model during online:-
- KLV-46EX400
Line : D2
Quantities : 83 sets
Input time : 8.45am
Aging time : 9.50am
Packing time: 11.50am
SMLD : No SMLD
Problem : FFC cannot lock to the power board
Remark : Lock at power board damage. Inform supplier
- KDL-46EX500
Line : D2
Quantities : 58 sets
Input time : 8.40am
Aging time : 9.30am
Packing time: 12.00pm
SMLD : No SMLD
Problem : Intermittent
Remark : Found overcrimping at terminal. Inform supplier.
Below is the illustration of the investigation skills used in determining the root cause of an event ;
Figure 19 : Investigation skills.
3.0 LESSON LEARNED AND EXPERIENCE GAINED
The author is imparted with a wealth of new knowledge and invaluable working experience during the internship period. In the working environment, the author has to quickly familiarize herself to the current work culture to develop the correct attitude and behavior to be taken to future undertakings. Some of the valuable lessons that have been learned are:
3.1 LEADERSHIP, TEAMWORK AND INDIVIDUAL ACTIVITES
For most of the tasks given, the author is usually teamed with one or more staffs to complete the tasks. Therefore, teamwork is vital to ensure that the tasks can be delivered successfully in a timely manner. Every player of the team was delegated with bits of the particular task to complete. All team player must assist each other in order to achieve a specific goal. Upon completion, every update must be relayed to every team player before the results are compiled. During the internship period, the author was actively involved with KAIZEN activities which require all members to cooperate. Besides that, the author was also a member of the winning the KAIZEN activities. Some of KAIZEN activities were leader by author. As the leader, author need to present the activities done by her group.
In doing individual tasks, the author has put a lot of commitment to complete each and every task in order to satisfy the task requirements. AT SOEM , the author has been treated as one of the permanent staffs by most of the employees and this has given the author much self satisfaction and confidence that greatly motivate her to perform better and better each time. Example, during author’s New Model online, author successfully follows the model without any support from other members.
3.2 BUSSINESS VALUE, ETHICS AND MANAGEMENT SKILLS
In LCD Production Department, ethics and management skills are among several values that have been emphasized to ensure that the department achieves its key performance indexes, which are the output quantity achievement versus planned output and the quality achievement.
Managing people, especially production operators efficiently are very crucial to ensure that all TV sets produced are free of defects and the process must follow SOP. Other than that, the author has been given a chance to train new operators on working ethics in LCD Production to develop good performance among the new employees. Last but not least, the author has been observing the LCD Production Department Management manage its employees, and learnt that in order to gain control, a leader has to earn respect.
3.3 SAFETY TRAINING AND VALUE OF PRACTICAL EXPERIENCE
Safety is a very crucial in the manufacturing industry since it involves a large amount of manpower. On the first day of registration in SOEM , the author was given an induction along with other trainees from other departments. The person in charge has given brief introduction on SOEM QESH Policy. After being transferred to LCD Production Department, the author has attended LCD Production Basic Training which also includes explanations on hazards, risks and critical processes in producing LCD TV. Other than that, the preparation for BVQI audit has given the author of the rough idea for safety requirement in a workplace. SOEM safety issues reporting, especially accident that occurs in SOEM is very much useful in circulating the accident, the cause of the accident and is a great tool to notify all members of SOME on recent accidents. The company reacts promptly upon the occurrence of any accident, and safety measures are to be taken before, during and after accident occurs.
By working in Japan’s Company, environment of working place is different with other company. During internship in SOEM, there is too much experienced get from there. Working with others departments make author knowing a bit of knowledge from them.
3.4 Problems or Challenges Faced
The first few weeks at Sony EMCS was very challenging for me. The working environment and culture was a whole new world for me. There were many new rules, information, procedures, operations and work responsibilities that need to be learned. I was also unable to fully depend on the other engineers and coworkers because of their own busy schedule. This situation forced me to be more independent, proactive and to develop the habit of actively asking questions about work related topics.
During my internship period, my coworkers would periodically delegate some of their work to me. Usually these works consist of carrying out tests, gathering information or processing paperwork. When carrying out these new tasks, I will have to follow the instructions given and ask for assistance if faced with any problems.
3.5 PQA Scope of Work
Being attached to the parts quality section had given the opportunity to acquire depth knowledge in the scope of work. This is beneficial as I was exposed to other scope that applies simulation process and execution procedure in daily operational, rather than in scope that are involved directly in designing and reviewing process development.
It is a good opportunity for me as having diversified knowledge will definitely be an advantage when seeking employment in the Engineering of Facilities field.
4.0 DISCUSSION AND RECOMMENDATIONS
The internship has met all the objectives and its success has surpassed my
expectations. It has opened my eyes to working life, enlightened me socially, and matured me as an adult. It has strengthened my technical base and enabled me to integrate theory with engineering practice. Finally, it has given me a clear sense of direction in my future studies and career as a electrical and electronics engineer.
In order for the next candidates to gain better knowledge and experience of working environment from the Industrial Internship Program, the author is strongly suggesting some recommendations to be reviewed by the Student Industrial Internship Unit (SIIU) and Sony EMCS (Malaysia) Sdn Bhd.
4.1 Student Industrial Internship Unit (SIIU)
Student Industrial Internship Unit (SIIU) should continuously update each available internship vacancies from various companies via the website instead of informing verbally to certain randomly picked students since verbal communication does not spread as widely as the website medium, leaving some students not aware of those available positions. If the offer is updated online, all students will have fair chances to know the details and choose which suits them.
Besides, before start the industrial training, students should be meet their Supervisor to get some advice about students’ expectations of the company’s environment and other. So, SIIU should be informing earlier to student about their UTP supervisor at least 2 or 3 weeks before start the Industrial Training.
4.2 Host Company – SONY EMCS (M) SDN BHD
SOEM should know the interest of student that had been attached to them and assign them to suitable department prior to their interest. This is very important to expose the trainees to the real environment of what they will be facing in the next 1 or 2 years. Apart from focusing on the student's interest, the plant supervisor should also acquaint the student to other departments so that they can extend their knowledge scope to other departments and understand the relation between each department. This way the student can understand the plant operation as a whole. SOEM should also assign each trainee to a specific project to focus on, instead of only doing daily routine to further explore the student’s capabilities. It is also recommended to send the trainees to training courses to develop the trainees.
As for the company benefit, the author recommends the SOP should be doing in two languages which are Bahasa Malaysia and also English. For those operators do not understand both languages, SOEM should give them class of Bahasa Malaysia and English. This recommendation highlighted due to interview between author and the operator. Most operators not understand what leader said and explanation in SOP.
Hopefully, the SIIU and SOEM could review these recommendations for the good of all parties involved. The improved training progr am should consider more in-depth roles and responsibility for the trainee where his or her actual capability is put to test.
5.0 CONCLUSION
The industrial internship program in Sony EM CS Malaysia Sdn Bhd has been completed within 32 weeks starting from 30th November 2009 until 9th July 2010. Basically, the author extend 1 week due to responsible to follow the project of New Model Fy’10. The projects and tasks that the author had been involved were very significant and beneficial. The valuable experience in PQA Department is a lifetime opportunity that very much affected the way that the author view life.
Completing industrial experience in SOEM provided the author with real world experience which will be extremely helpful in the transition into the industry later especially work in Japan’s Company. The author was given the opportunity to put knowledge into practice, as well as learning the importance of human relation skills. The author has developed a better social skill and nurtures the interpersonal traits. The ability to work in a team and with various people from different hierarchy level helps the author in enriching her soft skills. These have greatly improved her confidence level and have given further insight on what to expect while working in the industry. Besides, all staff at SONY is very friendly because they willing share their knowledge and experience with the trainee throughout they work in SONY. From all this happened, working in SONY is very good experience and this is the first step to the trainee towards being a professional person while working in the future.
Conclusively, the industrial internship program has achieved its objectives. The opportunity to work with various kinds of people is quite interesting, surprisingly so. The author has obtained an unexpected, yet invaluable perspective in engineering aspects that was not considered before the internship period. The author believes that all of these experiences will help in building a good career and a better person.
6.0 REFERENCES
- Secretariat of Sony Technical Standards Committee (1997). Sony Technical Standard: Preshipment test methods for packaged products (SS-00059), Eleventh edition.
- Ihsan , Emi, Faizal ( Parts Quality Assurance) reports.
- SOEM ISO 9001, Process Engineering & work instruction: Work instruction of part approval.
- (2009). Kaizen Report
-
Human resource development, Sony Corporation (1992). VA Basics, 2nd edition (pp. 39).
-
Part and Materials Intelligence Asia, SLS (2001). Value Analysis 3rd grade training (pp. 12, 32).
APPENDICES
APPENDIX A : KAIZEN REPORT
APPENDIX A
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SONY EMCS (MALAYSIA) SDN. BHD.
