Week 2 (26/7/2020 - 1/8/2020)
27/7/2020 (Monday)
Working time: 8:30am – 6:00pm
- I started my day by helping an internship trainee finding lot assigned by Mr KL Tang.
- We went to SMT Department and used the computer to track down the lot
- The lot was currently at the ‘pre-mold bake’ process at OV#3
- We went to MCOB Department to look for the machine but the technician in charged informed us that OV#3 has been moved to P34 which is at Batu Kawan.
- Mr KL Tang assigned me to measure pallets using OGP Machine, 30 for each auto and manual pallets respectively.
- Each pallet required 4 measurements: inner width, outer width, inner length and outer length.
- I wrote my own program to measure both type of pallet using OGP Machine applying the knowledge I gained last Friday
- By 4:00pm, I was only able to find 20 manual pallets and 1 auto pallets since the pallets were fully used by the operators in the production line.
- After saving the data for the pallet measurement, I went to Level 3 Office to submit the data to an engineer in charged name Nurul Farida.
- Later, since I have done my task in the SMT Department, Kak Nurul asked me to stay in the office with her to help her sort out the data using Microsoft Office Excel.
28/7/2020 (Tuesday)
Working time: 8:30am – 6:00pm
- I updated on the work given by Mr KL Tang for last week.
- Analysed data of pallet measurement given yesterday
- Mr KL Tang explained on why I was required to measure those measurements yesterday (to estimate the amount of tolerance that can be given when the pallet is run in the production).
- Assigned to measure 5 auto pallet using OGP Machine and data must be sent to Mr Chin Haw.
- Next, I went to FAVI to learn on how to analyse variance obtained on last Friday using Microsoft Office Excel.
- Kak Nurul gave brief explanation on how to sort out daily yield using Microsoft Office Excel.
- After lunch break, Mr Tang asked to meet him up at his office to explain the process flow of MCOB production.
- He also explained that the highest defect percentage are contributed by two types of defect which are PCB scratches and variance.
- He asked me to inspect the machine and process that has possibility to contribute these defects. This is called process-mapping.
- First, I went to FAVI to learn more about PCB scratch.
- Kak Nurul showed me a few images of lot that has PCB scratches.
- Then, Kak Nurul and I went to MCOB Department to start process-mapping.
- Since the production of MCOB includes many processes, Mr Tang asked me to start my inspection and observation from tape mounting process.
- He asked me to observe random 5 lots in for each process.
- I took note of the lot number to be reported to Mr KL Tang later.
- At this department, I inspected 6 processes, each process I observe around 5-6 lots. (Processes: tape mounting, tape cure, sawing, washing, edge removal, poking)
- To analyse, the lot that contains PCB scratches are at the tape mounting machine.
- 3 panels out of 6 lots at tape mounting experienced PCB scratches. Thus, some of the panel has the scratches before tape mounting is carried. Therefore, there is possibility that the scratches came from the processes before tape mounting.
- Then, I went to the other MCOB Department, specifically at the separating machine.
- I noticed that out of 10 lots I observed, 4 panels contain light scratches before separating is done.
- This means that the PCB scratches are not caused during the separation process.
- To reconfirm, the panels with scratches are observed using microscope to get a clearer view.
- According to Kak Nurul, those light scratches can sometimes appear similarly to another type of defect called contamination.
- All data including the lot number, the type of scratch, the panel number and a few photos were updated to Mr KL Tang.
- After finishing my task on the PCB scratches, Kak Nurul asked me to observe fly-off units that came from each FAVI.
- I found out that FAVI machines that process smaller unit such as DODGE has higher possibility to have fly-off unit.
- This explains the variance of the unit.
29/7/2020 (Wednesday)
Working time: 8:30am – 6:00pm
- I went to MCOB Department to gather data of the quantity in and out of each FAVI Machine.
- These data are important to determine the yield of each machine.
- The data are sorted using Microsoft Office Excel.
- Next, Kak Ida and I went to SMT Department as assigned by Mr KL Tang.
- She explained the ongoing processes involved in the SMT production line
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- She also explained that there will be some changes in the order of the processes with some new addition processes to improve the quality of the product.
- This is because, after AOI Porcess, the lots are going to undergo top inspection and bottom inspection at the OQA. If there is reject during the OQA, the operators will return the panels to undergo AOI all over again. This current process flow is time-consuming. Therefore, the company proposed a new process change.
- With this new proposed process changes, the OQA will have no returning panel to undergo AOI twice.
- Kak Ida and I has to observe the total duration of this new process flow.
- However, we have to have the agreement from the engineer in-charge of the processes before proceeding with the process changes.
- After lunch break, I went back to MCOB Department to continue gathering data.
- Then, I was taught to create the Pivot table from the data data collected and analysed it.
- I also learnt to create Pareto Chart based on the data.
- At around 3:00pm, I went to SMT Department to continue the process of implementing the process changes.
- Kak Ida and I went to get 3 lots of DODGE and run the process changes.
- The DODGE lots were taken randomly from the lots that have been through PCB Cleaning and waiting to be run in the AOI Machine.
- The 3 lots were pushed to be 100% bottom and top inspection.
- Then, according to the new proposed process changes, the lots have to enter the AOI Machine.
- However, the all of the AOI Machines were down. Therefore, we have to continue tomorrow.
30/7/2020 (Thursday)
Working time: 8:30am – 6:00pm
- I started my day by going to Level 3 Office where Kak Ida was there at her table.
- An IT Engineer installed a few software applications into my laptop to be used during the documentation.
- Kak Ida taught me a few things about data gathering using the application installed.
- Then, she introduced me to some techniques to analyse data using Microsoft Office Excell.
- The, I went to the SMT Department to look up for new lots to implement the new process changes.
- No lot is available for that moment because most of them were pending at the PCB Cleaning process.
- Therefore, I went to the MCOB Department.
- I continue doing the data gathering I did yesterday.
- Then, I met Kak Macitah, an engineer there. She asked me to help her measure character size for every unit from different package.
- She handed me rejected unit of Desmond, Siduri, Bates, Alloro, Dogdge and Hanzell to be measured.
- After lunch break, I went to the SMT Department to continue look up for the availability of the lot for the process changes purpose.
- Since there was no lot available, I started to measure the characters size that were requested by Kak Maci using the OGP Machine.
- I measured the character size (width and height) along with its thickness.
- All data were gathered and sent to Kak Maci.
- Right after I finished measuring, there were 2 lots of Dodge and 1 lot of Nightwing available on the rack.
- Since the OQA Operators were quite busy, therefore I decided to run through 1 lot of Nightwing consist of 6 panels only.
- First, I went to an OQA Engineer to ask for her help to run the 100% bottom inspection on the lot but she said that there are a lot of pending lots at the OQA. Thus, she could not help.
- Therefore, I went to an operator called Bapak, to ask for his help finding an available operator to help me out.
- Bapak assigned Kiki, an Indonesian operator to help me run the bottom inspection. I took track of the time for the inspection of each panel.
- Then, I went to find another operator to run the top inspection. Since there was no operator that was available, I decided to do it by myself. I asked out Abang Farhan to teach me to do the top inspection and then I did it to 4 panels.
- Another 2 panels were done by an operator there.
- After the top and bottom inspection were done, I sent the lot back to the rack to be proceeded with the AOI process.
- After gathering all the data, I sent to Kak Ida as an update.