TABLE OF CONTENT

PAGE
1. INTRODUCTION 2

1.1 INTRODUCTION FOR INDUSTRIAL TRAINING 2

1.2 THE OBJECTIVE OF INDUSTRIAL TRAINING 2

1.3 THE SCOPE OF INDUSTRIAL TRAINING 3
1.4 SUMMARY FOR REPORT 3

2. THE BACKGROUND OF INDUSTRY 5

2.1 THE PROFILE OF COMPANY 5

2.2 STRUCTURAL ORGANIZATION 6
2.3 MY DEPARTMENT 7
2.4 THE FLOW OF PROCESS IN THE INDUSTRY 7

3. OVERALL INFORMATION FOR TRAINING 20

3.1 KITTING SYSTEM IN TOOL 20

3.2 GRINDING MACHINE 23
3.3 LASER CUT & TURRET PUNCH MACHINE(COMBO) 25
3.4 AUTO CYCLE LOADER ASR-48M 28
3.5 TURRET PUNCH MACHINE 29
3.6 SHEARING MATERIAL MACHINE 29
3.7 ELECTRONIC CARBIDE METAL IMPREGNATOR 30
3.8 FORKLIFT 32

1
 4. SPECIFIC INFORMATION FOR TRAINING 33

4.1 THE IMPORTANCE OF LEARNING ALL THE MACHINES AND

EQUIPMENT 33
4.2 THE PROCEDURE OF WORK IN SYSTEMATIC AND EFFICIENT

WAYS 33
4.3 PROBLEM-SOLVING METHOD ON THE PRODUCT OF FIRST
BLANKING PROCESS 47
4.4 MAINTENANCE FOR MACHINE AND TOOL 50

5. CONCLUSION

5.1 CONCLUSION FOR INDUSTRIAL TRAINING PROGRAMME 51

5.2 PROBLEMS AND SUGGESTIONS 51

LIST OF FIGURES

FIGURE TITLE
PAGE

2.1 WONG ENGINEERING 6

2.2 CORPORATION STRUCTURE 7
2.4.1 ALUMINIUM CHROMATING PROCESS LAYOUT 18
2.4.2 ALKALINE ZINC PROCESS LAYOUT 19

2
3.1(a) THE PART OF TOOL 22
3.1(b) THE DIFFERENCE BETWEEN STANDARD TOOLING
AND AIRBLOW TOOLING 22
3.1(c) TURRET DIAGRAM 24
3.2(a) GRINDING MACHINE 25
3.2(b) DULL RE PUNCH HEAD 26
3.3(a) EML MACHINE 26
3.3(b) EML MACHINE’S LAYOUT 27
3.3(c) CNC PANEL 28
3.3(d) TOOL CHANGE DOOR 28
3.4 AUTO CYCLE LOADER ASR-48M 30
3.6 SHEARING MATERIAL MACHINE 31
3.7(a) ELECTRONIC CARBIDE METAL IMPREGNATOR 32
3.7(b) GUN RECEPTACLE 32
4.3.3(a) THE METAL PLATE WITH CONNECTOR 49
4.3.3(b) THE WELDED POSITION FOR GUN RECEPTACLE
AND DIE 50
4.3.3(c) THE REFERENCE OF SETTING POWER FOR METAL
IMPREGNATOR 50

3
 CHAPTER 1 INTRODUCTION

1.1 INTRODUCTION FOR INDUSTRIAL TRAINING

As part of graduation requirements, all the undergraduates, the third year and forth year
students, who take bachelor of mechanical engineering in UTM will undergo industrial training
programme for a duration of ten weeks. This industrial training is a course for undergraduates
that gives them an opportunity to expose themselves in the real career world so as to they will
learn how to relate theoretical learning before and real practical in working’s environment.
Besides that, in future, they will be having good preparation and understanding for their field of
profession.

4
1.2 THE OBJECTIVE OF INDUSTRIAL TRAINING

i. Undergraduates have an opportunity to expose themselves in working’s environment of

their field of profession respectively.

ii. For obtaining working’s experience in the industry which is relating to their field of
current study.

iii. Using knowledge which is obtained from industrial training for their study after finishing
training and continuing study at university afterwards.

iv. Training them to be capable in communication and interaction between workers and
superior.

v. Training them to be able to prepare a technical report which is related to industrial

training they do.

vi. Cultivating them to work as a team.

vii. Learning to be professional behavior respectively.

1.3 THE SCOPE OF INDUSTRIAL TRAINING

5
 i. Observing the whole operation of this industry.

ii. Doing operation’s work that is involved in unit production by either using machine or
tool.

iii. Work that involving installment and fabrication of tool.

iv. Visual inspection and quality control on the final product.

v. Repairing any damaged tool if it still can use, or buying a new tool to replace it.

vi. Discussion and meeting with superior.

1.4 SUMMARY FOR REPORT

During the ten weeks of my industrial training, this industry allocated me as a beginner at
the laser and turret punch sub-department which was involving primary process of the product
and it belonged to manufacturing department. In the first day of the week, after visiting all the
departments in this industry, I was given a task to learn about kitting system that I must know all
the tools in those four cabinets. Indeed, I had to prepare a set of tools by according tooling list
after I mastered all the tools.

After a week, I was given a manual book to learn how to operate those machines. There
were a lot of machines at my sub-department; grinding machine, two turret punch machine, laser
cut machine, one set of laser cut with turret punch combo machine, shearing material machine
and auto cycle loader which was attached to that combo machine. After several weeks, I was

6
starting to learn some new things. There were some technical skills I had to learn such as using
electronic carbide metal impregnator, tooling maintenance and driving forklift’s skill.

Before I left this industry, I had to teach a few of new workers to learn all the knowledge
I had been learned since I was worked here. I was started to teach them during ninth week and
tenth week.

7
 CHAPTER 2 THE BACKGROUND OF INDUSTRY

2.1 THE PROFILE OF COMPANY

Figure 2.1 Wong Engineering

8
 Wong Engineering was established in October 1982. The company has since grown to
become the leading manufacturer for high precision component parts in Malaysia. Located in
the High Technology Park close to Penang in Northern Malaysia, Wong Engineering has ready
access to tap into a pool of highly skilled professional talents in wide spectrum of industry
sectors like Electrical & Electronic, Semi-conductor, Biotechnology, etc. This has help put
Wong Engineering in a favorable position to offer its customer a competitive edge in
manufacturing need.

Wong Engineering also provides product design, development and manufacturing

services to its customers from wide spectrum of industries including the Oil & Gas, Aerospace,
Telecommunication, Test Instrument, Automotive and Medical Devices sector.

Today Wong Engineering offers its customer a one-stop value added mechanical solution
that encompasses the whole supply chain till the final assembly and delivers them with the right
timing, pricing and quality.

2.2 STRUCTURAL ORGANIZATION

Wong Engineering
Corporation Berhad

9
 Wong Engineering Wong Engineering WEC Marketing
Industries Sdn.Bhd. Electronics Sdn.Bhd. Sdn.Bhd.
(Precision Sheet Metal (Precision Metal (Environmental &
& Assembly) Turned Parts) Heath Products)

Wong Exerion Precision

Technology Sdn.Bhd.
(Precision Technology in
Welded Frames)

Figure 2.2 Corporate Structure

WEC Marketing
Sdn.Bhd.
2.3 MY DEPARTMENT (Environmental &
Heath Products)

There are many sub-departments in the manufacturing department. Each sub-department

has different process respectively. The sub-departments are shearing material department, laser
cut department, turret punch department, pending for filing department, sanding department,
WEC Marketing
DET department, bending department, visual mechanical inspection department, insert nut Sdn.Bhd.
(Environmental &
department, spot-weld department, packing department, SUBCON department, IQA dimension WEC Marketing
Heath Products)
Sdn.Bhd.
and visual inspection department, QQA final inspection department and finish good store (Environmental &
Heath Products)
department. Furthermore, same as manufacturing department, production control department
and development department that both departments also have their sub-departments.

After visiting all the sub-departments, I was sent to the turret punch department. My
department is very important towards industry because major income came from my department.
In addition, my department was primary process that is blanking process from a sheet of metal

10
which went through the punching machine and eventually the product will be done after running
the program. The product of first process will be carried out in other departments. For example,
the product will be sanding in order to remove scraps, but usually it depends on customer’s
request.

2.4 THE FLOW OF PROCESS IN THE INDUSTRY

FIRST PROCESS – BLANKING

A SHEET OF
METAL

EML MACHINE (LASER

CUT & TURR ET PUNCH
COMBO )

11
 PRODUCT OF FIRST PROCESS

SECOND PROCESS – SANDING

PRODUCT OF
FIRST PROCESS

SANDING

12
 FILING

PRODUCT OF SECOND PROCESS

THIRD PROCESS – DIE (DEEP IN EMBOSS)

PRODUCT OF
SECOND
PROCESS

WEC Marketing
Sdn.Bhd.
(Environmental &
Heath Products)

EMBOSSING

13
 PRODUCT OF THIRD PROCESS

FORTH PROCESS – BENDING

PRODUCT OF
THIRD PROCESS

BENDING

14
 PRODUCT OF FORTH PROCESS

FIFTH PROCESS – VISUAL MECHANICAL INSPECTION

PRODUCT OF
FORTH PROCESS

VISUAL MECHANICAL INSPECTION

15
 PRODUCT OF FIFTH

SIXTH PROCESS – INSERT NUT

PRODUCT OF
FIFTH PROCESS

INSERT NUT

16
 PRODUCT OF SIXTH
PROCESS

SEVENTH PROCESS – SPOTWELD

PRODUCT OF
SIXTH PROCESS

SPOTWELD

17
 PRODUCT OF SEVENTH
PROCESS

EIGHTH PROCESS – PACKING

PRODUCT OF
SEVENTH
PROCESS

PACKING

18
 PRODUCT OF EIGHTH PROCESS

OTHER PROCESS – SUBCON (ZINC PLATE AND YELLOW CHROMATE)

BEFORE ETCHING ETCHING

19
ACID DIPPING OVEN

20
Figure 2.4.1 Aluminium Chromating Process Layout

21
Figure 2.4.2 Alkaline Zinc Process Layout

22
QUALITY CONTROL

IQA DIMENSION AND VISUAL QQA FINAL INSPECTION

INSPECTION

This department will check every process of
bind off’s form that checking first part in a
sheet metal before continuing the remaining
parts. If the first part of a product is rejected,
then the remaining part of a sheet metal that
will stop cutting or punching the product out.
It will keep repeating the first part until
achieving the approved product.
This department will check the final products
before it delivers for customer. If the final
products are rejected, it will hold out for awhile
either put in the store or send it back to
production if the final products can be remade.

CHAPTER 3 OVERALL INFORMATION FOR TRAINING

23
3.1 KITTING SYSTEM IN TOOL

Kitting system is very vital work that needs someone to prepare tools by referring to
tooling list for an operator and always keep all the tools in the cabinets in a good order. Those
cabinets must always keep clean and tidy. This work is likely as an assistant operator. Firstly, I
have to get knowledge about all varieties of tool and its function as well. The part of a tool will
be shown in the figure 3.1(a).

DIE STIPPER

PUNCH HOLDER

24
 GUIDE

Figure 3.1(a) The part of tool

In my department, there are two brands of tools. They are AMADA TOOL and
WILSON TOOL. Both of them have their own significant design and function respectively.

AMADA TOOL is an airblow tooling which can ensure optimum tool life. It means it
still maintains its component quality after 30,000 hits. In figure 3.1(a), it is shown the difference
between standard tooling and airblow tooling.

Standard tooling Airblow tooling

after 30,000 hits after 30,000 hits

Figure 3.1(b) The difference between standard tooling and airblow tooling

WILSON TOOL does not have airblow inside the tool. However, this tool is more
convenient than AMADA TOOL, it can be set up easily. When changing any size of punch head
and die, it is merely replacing punch head, die and stipper; guide and holder do not need to
change. For example, the figure 3.1(a) is a set of WILSON TOOL. The people who is working

25
at CAD room that their basic job is to create tooling list, production schedule and computer
program. Moreover, ordering new tool is a part of job for CAD room’s people. Therefore, it is
only necessary to buy punch head, die and stipper if they want to order any particular size of tool
but it depends on customer’s drawing.

Every die has their tolerances. For instance, tolerance = ± 0.25 mm, tolerance = ± 0.35
mm, tolerance = ± 0.65 mm. The size of tolerance for a die will be selected whom base on
thickness of a sheet metal and type of material. There are five types of punches which are
round(RO or RD), rectangle(RE), square(SQ), oblong(OB) and special tools(SP). Special tools
are tools that the tools have any type of pattern and shape but excluding tools which are
mentioned before. Every special tool has their SO number respectively. For example, one of
special tools is countersunk tool and its SO number is SO: 643899-10. Furthermore, special
tools are including marking tool, banana tool, slotting tool, cluster tool, semi corner radius tool,
emboss tool, SE(down) tool, T-tool Fermi-T shape tooling, micro joint tool and so forth.

Besides that, there are different types of station for tooling. The tooling classifies
becoming bigger and heavier in the arrangement below. More details has been shown in figure
3.1(c).

A station < B station < C station < E station < G station < H station

SIZE, WEIGHT, COMPLEXITY OF TOOL ARE

INCREASING

26
 A
STATION

B
STATION

C
STATION

E
STATION

G
STATION

H
STATION

Figure 3.1(c) Turret Diagram

Above all, after understanding all the details in tooling, set up tool and tooling
preparation will be no problem. This is all about kitting system that it seems very simple work
but actually it needs knowledge and technical skills to master it. Maintenance on tooling also
regards as a part of kitting system that it will be discussing in chapter 4.4.

3.2 GRINDING MACHINE

27
 Grinding machine is a very important machine that it can be functioned as sharpener for
turret punch tooling. It can grind any punch head in the length between 0 mm and 0.99 mm.
The punch head which has wore out already that needs to be ground since it have been using
regularly. The example of dull punch head has been shown in figure 3.2(b). The machine is an
automatic grinding machine and its model is TOGU-IILEXP (AMADA). The grinding machine
has been shown in figure 3.2(a).

Figure 3.2(a) Grinding Machine

28
 The top of punch
head was dull. It is
obviously the edge
of RE punch head
was corner-rounded
a bit.

Figure 3.2(b) Dull RE Punch Head

3.3 LASER CUT AND TURRET PUNCH MACHINE (COMBO)

Figure 3.3(a) EML Machine

This machine is the most expensive machine in this industry. The EML machine has
been shown in figure 3.3(a). It costs eight-figure approximately. It needs nitrogen gas, oxygen
gas and laser gas for laser cutting. The EML machine’s lay out has been shown in figure 3.3(b).

29
Figure 3.3(b) EML Machine’s Lay Out

30
 Figure 3.3(c) CNC Panel

Toolin
g

Figure 3.3(d) Tool Change Door

In figure 3.3(c), it is CNC panel that it uses for computer program. In figure 3.3(d), it is a
tool change door that it uses for changing tools.

All the gaseous tanks are ordered from MOX companies that they are very costly. Thus,
the EML machine is the highest expenses in this industry. Apart from the machine is very
expensive, its performance is undoubtedly efficient and accurate. Despite of unusual shapes or
patterns or degrees that it seems very difficult to cut the product out, a high quality product will

31
be produced that is matching exactly with the drawing of product and all the dimensions are
precise and standard. By comparing to a normal turret punch machine, the advantages of EML
machine are reducing the possibility of overloading and overlapping tooling in the machine. The
overloading and overlapping cases will be discussed in chapter 4.1.

In general, this combo machine can use for punching and cutting out material.

3.4 AUTO CYCLE LOADER ASR-48M

It also called as material cycle changer. It is a machine that is a part of the EML machine
but it has its own CNC panel. It means it cannot be controlled by EML’s CNC panel which only
connects to it.

The machine has been shown in figure 3.4. The advantage of this machine is able to pick
the sheet metal into the EML machine consecutively. Instead of some material is being carried
by workers that the material is heavy and impossible to move, the machine can solve this
problem. Especially, cold rolled steel(CRS), copper, hot rolled steel(HRS) and electro
galvanized(EG) and galvanized steel zero regular spangle(GI), these are heavy materials.

32
 Figure 3.4 Auto Cycle Loader ASR-48M

3.5 TURRET PUNCH MACHINE

There are two turret punch machines in this industry. Both of them seem to be
similar in function but they are different in models which their models are EM 2510NT
and VIPROS 2510 KING. They can only punch material but cannot cut material.
However, these machines can make the product easily to remove without cutting but
punching around the shape out of the sheet metal and the edge of the product is merely
tiny joins between product and frame of sheet metal. These joins can be broken by using
screwdriver with flat head.

3.6 SHEARING MATERIAL MACHINE

Shearing material machine is a machine that is used for cutting material which is the rest
of sheet metal after product has been taken out in order to separate the frame of product and the

33
remaining material which is still uncut. The remaining material can be used when it is necessary.
Sometimes some materials need to cut out first before using at turret machines, a sheet metal
may be cutting to several pieces. This is a precaution for avoiding scratches or bending on the
product. If the product needs to be punching like ‘bee nest’ in shape and the whole sheet metal is
only able to produce six products, it will occur bending on the surface. There is no problem if a
sheet metal is cutting to six pieces and each piece for one product.

In the case of scratches on the product, it is due to the heavy material and the scraps is
stuck inside the dies which is inside the machine will rub with the surface of sheet metal below.
There is no problem if a sheet metal is light and thin. The shearing material machine has been
shown in figure 3.6.

Figure 3.6 Shearing Material Machine

3.7 ELECTRONIC CARBIDE METAL IMPREGNATOR

34
 Electronic carbide metal impregnator is a device that is used in order to prevent any scrap
jump on the surface of sheet metal when the machine is running. The gun receptacle has to plug
in the electric discharge selector, then adjusting volt and it is ready to use. More details will be
discussed in the chapter 4.3.

Figure 3.7(a) Electronic Discharge Selector

Figure 3.7(b) Gun Receptacle

35
3.8 FORKLIFT

As we all know, forklift is really useful for carrying anything that human cannot carry it.
In this industry, there have six forklifts which are automatic gear. It is easier to drive an
automatic forklift than manual forklift.

36
 CHAPTER 4 SPECIFIC INFORMATION FOR TRAINING

4.1 THE IMPORTANCE OF LEARNING ALL THE MACHINES AND EQUIPMENT

It is quite headache if you cannot find the suitable station of a tool for machine, so there
are some equipment you can use to change any station of tool to suitable station of tool. The
equipment are adapters. For example, there is only 3x1 mm, RE, A station of tool can use
adapter to become B station of tool. There are two types of adapters which are A station to B
station and B station to C station. Both of two types of adapters can stack together as a result A
station to C station.

It is not quite reliable by using program from CAD room and transferring it through
diskette to CNC panel. In the case of overlapping, it means the machine is having two or more
tool which is same size, shape and station. For example, there are two tools which are 15x3 mm,
RE, B station in the machine. Consequently, it will cause overloading tool in the machine that
means too much tools in the machine and becomes burden to the machine. We can settle these
problems by placing one tool in the location of auto index station. Auto index station can rotate
any tool to any degree. In contrast, sometimes programmer sets one tool at 0 degree and another
tool at 90 degree that both of tools are same, but putting one tool in the auto index station is more
preferable. After placing tool in the auto index station, we must edit the program by changing
the station number.

37
 It needs to edit the program if all the pallets of sheet metal are empty, because we can
reuse the remaining material which is still uncut. Therefore, without knowledge how to edit the
program you will affect the schedule of running product.

4.2 THE PROCEDURE OF WORK IN SYSTEMATIC AND EFFICIENT WAYS

In this industry, all the workers must do their tasks in a great order. Each step for
procedure of work must follow step by step instruction in order to prevent any accident happens
and any missing step of work that will influence the final product. In fact, there is a daily
schedule we must follow to ensure how many products will be produced within days, months or
even years. There are few procedures of work I would like to discuss.

4.2.1 THE EML MACHINE FLOW

START UP EML MACHINE FLOW:

38
39
40
41
OPERATING EML MACHINE FLOW:

42
43
44
45
46
4.2.2 EML MACHINE SCHEDULE FLOW FOR TURRET PUNCH DEPARTMENT

My department is only involving blanking process which is primary process. After

finishing the product of first process, it will transfer to other department to continue the next

47
process. However, each department has their own schedule that they must obey it. If any
department cannot finish their product on time, they will have to work on weekends or overtime
(OT) during weekdays. The schedule flow has been shown in the following below.

48
49
50
51
52
4.3 PROBLEM-SOLVING METHOD ON THE PRODUCT OF FIRST BLANKING
PROCESS

Sometimes the products get rejected are not because of the workers do not follow the
step-by-step instruction, in actual fact, they are ignoring some trivial issues without carefully.
More details will be discussed in the following below.

4.3.1 DIMENSION PROBLEM

If the thickness of material is greater than 1.6 mm (such as 1.8 mm, 2.0 mm, 2.3 mm, 2.4
mm or 2.5 mm), you have to increase the size of die but maintain the size of punch. For
example, if the thickness of aluminium is 2.0 mm and RO 3.3 mm of tool is required, the die of
tool should change to 3.5 mm by taking other die of the tool. The increasing of size of die can
increase the tolerance for overcoming that material with larger thickness. This can prevent the
punch head of tool is damaged by the material and the product as well.

4.3.2 MATERIAL PROBLEM

53
 Normally, the problem about material is because of the origin of sheet metal. There are
two cases that have happened about problem of the material. The first case is the sheet metal has
occurred scratches that the surface of sheet metal may be caused by the metal manufacturer. The
second case is the mistake of given information for the thickness of material. For example, the
sheet metal we have ordered is 1.6 mm Aluminium, but the metal manufacturer gave us 1.8 mm
Aluminium. We can solve the problem by ordering the sheet metal with laminated plastic.
However, the laminated sheet metal is not suitable for EML machine, because it will cause
burning on the sheet metal due to the laser cut. So it is only used for turret punch machines;
VIPROS 2510 KING and EM 2510NT.

4.3.3 TOOL PROBLEM

There are several cases that the machine is out of order because of the problem of tool.
The first case is the die has stuck with scraps as a result the die was broke. The second case is
the punch head has stuck in the die and the material in the middle of them. It may be caused by
the tool which was dull and the tolerance of die was not suitable or too small in size. The third
case is the operator is reckless when he is setting up tool in the machine, he put the die in the
wrong location of station. Consequently, the tool was damaged and machine will stop working
because of these problems. However, these problems can be solved by using metal impregnator
to improve the performance of die. The method of using metal impregnator has been shown in
figure 4.3.3(a), (b) and (c).

54
 Figure 4.3.3(a) The Metal Plate With Connector

Figure 4.3.3(b) The Welded Position For Gun Receptacle And Die

55
 Figure 4.3.3(c) The Reference Of Setting Power For Metal Impregnator

Normally, the power of 50 will be preferable. After using metal impregnator on the die,
the scraps will neither jump on the surface of sheet metal nor stick inside the die.

4.4 MAINTENANCE FOR MACHINE AND TOOL

The maintenance for machine and tool are extremely important work for us in order to
keep them in good performance all the time. The EML needs to fill up lubricants and oils if
machine’s tanks are empty or low level. Besides, the air dryer needs to clean every month if not
the machine will stop working.
In addition, the service of tool is necessary every week. The punch head of tools have to
grind if they are dull or not sharpen. Sometimes we use lime with blue oil to clean at the side of
punch head in order to make it smooth and flat.

56
 CHAPTER 5 CONCLUSION

5.1 CONCLUSION FOR INDUSTRIAL TRAINING PROGRAMME

In conclusion, I would like to conclude that I have learned a lot of knowledge which I
cannot obtain in the books or references. Even though it is only ten weeks of training, the

57
experience in the industry during ten weeks is valuable for me. I have learned to be responsible
for my position and be punctual on work. It can be said that “Patience is bitter, but its fruit is
sweet.”

5.2 PROBLEMS AND SUGGESTIONS

There are some problems I have to face with them. The distance between industry and
my house is 22 km. The usage of fuel is costly towards me. But fortunately the industry has
given me allowances of RM 500 for every month. I was living in my house during ten weeks.
Therefore, I still have earned money a bit. It is helpful if our faculty is giving some allowance
for those trainees who have to rent house themselves.

58