COMPANY INTRODUCTION
Azman Hamzah Plastik Sdn Bhd, founded in the year 1989, has firmly established itself as a leading player in the field of Precision Plastic Injection Moulding and Module Assembly, with a strong emphasis on serving the Automotive Industry. With its headquarters strategically located in Shah Alam, Selangor, the company has taken significant steps to enhance its operational reach and efficiency. This commitment to excellence has led to the expansion of manufacturing facilities in both Bukit Beruntung, Selangor, and Tanjung Malim, Perak, enabling Azman Hamzah Plastik to maintain a close and responsive relationship with its valued customers.
Azman Hamzah Plastik Sdn Bhd's primary focus lies in Precision Plastic Injection Moulding and Module Assembly, offering a wide range of innovative solutions tailored to meet the exacting standards of the automotive sector. By continuously investing in its facilities and technologies, the company ensures that it remains at the forefront of the industry, delivering high-quality products and services to its clients.
The decision to expand its manufacturing presence in key locations, such as Bukit Beruntung and Tanjung Malim, underscores Azman Hamzah Plastik's dedication to customer satisfaction. By strategically positioning itself near its customer base, the company can respond quickly to evolving market demands and provide efficient support to its partners in the automotive sector.
In summary, Azman Hamzah Plastik Sdn Bhd, established in 1989, is a renowned player in the field of Precision Plastic Injection Moulding and Module Assembly, with a strong focus on serving the Automotive Industry. Through its strategically located headquarters in Shah Alam, Selangor, and expanded manufacturing branches in Bukit Beruntung, Selangor, and Tanjung Malim, Perak, the company maintains its commitment to excellence and customer proximity, ensuring that it continues to be a trusted partner in the automotive manufacturing sector.
Vision, Mission and Philosophy of Company
Vision
To be a progressive and dynamic plastic automotive component manufacturer, renowned in the region
Mission
To be recognized and acknowledged as a leading original design manufacturer of automotive plastics component, that emphasizes on innovation and competitiveness.
Philosophy
"To Develop Highly Motivated Team Member. With Good Manufacturing Practise to ensure Good Quality Product to Delivered on Tome With Competitive Price to Customer."
WEEK 1
Weekly Activity Highlight : Introduction to Workscope
Upon joining the Research and Development department as a technical assistant intern, I was delighted to learn that my primary focus would be on handling the Proton project under the guidance of En. Syahmi, Technical Executive of Research and Development Department and also the Project Leader for AHP Proton project. This exciting opportunity allowed me to delve into the world of automotive design and innovation. The scope of my work involved contributing to the design and production of the interior and exterior plastic parts for the Proton SS-11 (S50) models.
WEEK 2
Weekly Activity Highlight : Assisting the mould trial of SS-11 parts FRAME MODULE
Figure 1 : Quality inspection of FRAME MODULE
1. Summary: The weekly activity highlight involved active participation in the mold trial for SS-11 parts, specifically the FRAME MODULE. The primary focus was to assess the mold's preparedness for regular production and address identified defects in the injected parts. Notable issues included a burn mark at the edge of the module frame and the presence of excess runner gates, highlighting the need for corrective measures. The overarching goal was to ensure the mold's readiness for ongoing production while maintaining stringent quality standards for SS-11 FRAME MODULE parts.
2. Knowledge Gain: Participating in the mold trial provided valuable insights into the intricacies of the injection molding process, specifically for the SS-11 FRAME MODULE. It enhanced understanding regarding the critical parameters influencing the quality of injected parts, including the prevention of defects such as burn marks and excess runner gates. The experience also deepened knowledge regarding the importance of proactive measures in maintaining high-quality standards during mass production. Understanding the nuances of molding parameters and defect mitigation strategies contributes to a more comprehensive grasp of the manufacturing processes.
3. Challenge and How to Overcome: The identified challenges, including the burn mark and excess runner gates, posed potential risks to the quality of the FRAME MODULE parts. To overcome these challenges, a proactive approach was adopted. The team conducted a thorough examination of molding parameters, making necessary adjustments to address the burn mark and excess runner gate issues. Collaborative problem-solving and effective communication among team members were crucial in devising corrective measures. This challenge underscored the importance of a comprehensive understanding of the molding process and the ability to adapt and refine parameters in real-time. The proactive approach ensured that corrective actions were promptly implemented, contributing to the overall success of the mold trial and paving the way for high-quality, defect-free SS-11 FRAME MODULE production.
WEEK 3
Weekly Activity Highlight : Learning how to prepare Standard Operating Procedure (SOP) for Injection Moulding and Assembly process
Figure 2 : Standard Operating Procedure of SS-11 part
1. Summary: The introduction to Standard Operating Procedure (SOP) preparation for the external parts of Proton SS-11, specifically focusing on the plastic injection molding process, serves as a critical foundation for ensuring quality and safety during mass production. The day's objective was to familiarize with the parts and their components, paving the way for the creation of SOPs for both the injection molding and assembly processes. The SOP development process involved understanding design requirements, breaking down the manufacturing steps, defining parameters, emphasizing quality assurance, incorporating safety protocols, and conducting effective communication and training. The significance of these SOPs lies in their role in maintaining consistent quality, ensuring safety, and enhancing overall process efficiency.
2. Knowledge Gain: This SOP preparation initiative contributed significantly to knowledge enhancement in various domains. Understanding the design and requirements deepened insights into the intricacies of external parts manufacturing. Breaking down the injection molding process into key steps provided clarity on the sequence of operations. Defining parameters allowed for a nuanced understanding of the variables influencing the production process. Learning about quality assurance measures underscored the importance of precision in manufacturing. Integrating safety protocols expanded knowledge on creating a secure working environment. Finally, participating in communication and training sessions enriched understanding in facilitating effective SOP implementation.
3. Challenge and How to Overcome: One potential challenge in SOP preparation is ensuring that the procedures are both comprehensive and easy to follow. This was addressed by engaging in clear communication and collaboration between the R&D engineer and machine operators. Thoroughly understanding design requirements and breaking down the process into detailed steps facilitated the identification of critical parameters. Defining these parameters required meticulous attention to detail to ensure accuracy. The challenge of incorporating safety protocols was addressed through careful consideration of industry standards and regulations, ensuring that the SOPs aligned with best practices. The training sessions conducted by the R&D engineer were instrumental in overcoming challenges related to effective communication, as they provided an opportunity for hands-on learning and clarification of any ambiguities in the SOPs. Overall, these challenges were navigated through a collaborative and detail-oriented approach, ensuring the SOPs are effective in guiding the manufacturing process.
WEEK 4
Weekly Activity Highlight : Assisting Checking Fixture measurement result (MR) for BASE REAR NUMBER PLATE.
Figure 3 : BASE REAR PLATE NUMBER Figure 4 : Gap ruler Figure 5 : Measuring gap on CF
1. Summary: The task of assisting in Checking Fixture (CF) measurement results (MR) for BASE REAR NUMBER PLATE is integral to ensuring the accuracy of injection-molded parts produced by the company. The measurement process involves utilizing tools like the Gap Ruler to assess the gap between the part and the CF body. Accuracy is paramount, and the measurements must fall within specified tolerance ranges for the part to be deemed accurate. Multiple measurements are taken to comprehensively evaluate the overall accuracy of the part.
2. Knowledge Gain: This activity contributes significantly to knowledge acquisition in quality control and measurement processes. Understanding the role of Checking Fixtures in assessing part accuracy provides insights into the critical elements of quality assurance in injection molding. Learning about the specific tools, like the Gap Ruler, and their application in measuring gaps enhances knowledge about precision measurement techniques. Additionally, gaining familiarity with tolerance ranges and the criteria for accurate parts deepens comprehension of quality standards in manufacturing.
3. Challenge and How to Overcome: One potential challenge in this task is ensuring the accuracy and reliability of measurements. Overcoming this challenge involves meticulous attention to detail and adherence to standardized measurement procedures. Calibration of measurement tools, including the Gap Ruler, is crucial to ensure their accuracy. Another challenge might be the interpretation of tolerance ranges and the application of these criteria in the assessment process. This is addressed through clear communication with quality control guidelines and, if needed, seeking clarification from experienced team members or supervisors. Regular training and updates on measurement techniques and quality control standards can further enhance the ability to overcome challenges in assessing part accuracy. The challenge ultimately becomes an opportunity for continuous learning and improvement in ensuring the precision and quality of injection-molded parts.
WEEK 5
Weekly Activity Highlight : Review of Standard Operating Procedures
Figure 6 : SOP reviewing process
1. Summary: The task involves a comprehensive review and enhancement of the Standard Operating Procedures (SOP) for all parts associated with the SS-11 project. This critical assessment is conducted collaboratively by two designated individuals, Cik Eifa from the Quality Assurance Department and En Nazmi from the Quality and Reliability Engineering Department (QRE). The primary objective during the initial release 1 stage is to refine the SOPs, focusing on format improvement, process accuracy, and adherence to labeling and standards. The review process involves meticulous scrutiny, with all comments and recommendations highlighted using a red color pen on printed A4 copies of the SOPs. This stage is pivotal in setting a robust foundation for the subsequent phases of the project.
2. Knowledge Gain: Participating in the review and enhancement of SOPs for the SS-11 project provides valuable insights into the meticulous processes involved in ensuring operational excellence. Knowledge gained includes a deeper understanding of the significance of standardized procedures in manufacturing, particularly in the automotive industry. The collaboration between the Quality Assurance Department and the Quality and Reliability Engineering Department enhances comprehension of the multifaceted aspects of quality control and reliability in engineering projects. Furthermore, the attention to detail in format refinement and the importance of adherence to labeling and standards contribute to a nuanced understanding of SOP development.
3. Challenge and How to Overcome: One potential challenge in this task is ensuring a harmonious collaboration between the Quality Assurance and Quality and Reliability Engineering Departments. Overcoming this challenge requires fostering effective communication channels and mutual understanding of each department's goals and perspectives. Regular meetings and discussions can help align expectations and ensure that the review process is comprehensive and constructive. Another challenge could be managing the volume of SOPs and comments efficiently. Establishing an organized system for cataloging and tracking changes, perhaps using digital tools, can streamline the review process and facilitate communication between reviewers. The challenge of maintaining consistency and clarity in marking SOPs with a red color pen can be addressed through a standardized set of markings or symbols, ensuring that comments are easily understood by all stakeholders.
WEEK 6
Weekly Activity Highlight : Identify and verify the child parts difference for Proton Saga MC gear shift lever
Figure 7 : 3D data of GSL SAGA MC2
Figure 8 : GSL SAGA MC2 (R-LINE)
Figure 9 : GSL SAGA MC2 (PREMIUM)
Figure 10 : GSL SAGA MC2 (STANDARD)
Summary: The task of identifying and verifying child parts differences for the Proton Saga MC gear shift lever across three variants—R-LINE, PREMIUM, and STANDARD—involved a meticulous process of examining the Bill of Materials (BOM) and detailed 3D dimension drawings. The goal was to pinpoint specific variations in child parts, and this was achieved through a thorough cross-referencing of the BOM and dimension drawings. The validation process included consulting with the leader of the GSL assembly line, confirming the identified differences, and gaining insights into their significance during assembly. Visual documentation through actual pictures was crucial for effective communication with the manufacturing team to ensure accurate assembly and maintain quality standards.
Knowledge Gain: This task significantly enhanced my understanding of the intricacies involved in variant-specific manufacturing within the automotive industry. It provided insights into how detailed documentation, such as BOMs and dimension drawings, plays a pivotal role in ensuring precision and consistency in the production of different product variants. Collaborating with the assembly line leader offered valuable practical knowledge about the real-world implications of these variations in the assembly process.
Challenges and How to Overcome: One of the challenges faced was the complexity of the BOMs and 3D dimension drawings, requiring meticulous attention to detail. To overcome this, a systematic and organized approach was adopted, breaking down the examination process into manageable steps. Consulting with the assembly line leader proved invaluable in clarifying ambiguities and understanding the practical implications of identified differences. Effective communication through visual aids, such as photographs, was essential to convey the identified variations to the manufacturing team accurately.
WEEK 7
Weekly Activity Highlight : RUN@RATE MOULD
Figure 11 : Run@Rate SS-11 parts with Proton PIC
1. Summary : Run@RATE (INJECTION MOULDING) The objective of run and rate of mould is to study and verify the quality of injected part. Other than that, it is also crucial for the recording of the actual cycle time of injection moulding, inspection and racking process.
2. Knowledge Gain : Able to judge and verify the quality of injected plastic parts. Next, I also get to learn how to calculate (theoretical) and record the cycle time (actual) of the injection moulding, inspection and racking process.
3. Challenge and How to Overcome : The actual cycle time is longer than theoretical cycle time causing lesser output produced in a period of time. The way to overcome this is by studying the bottleneck process and propose solution to cut short the bottleneck time.
WEEK 8
Weekly Activity Highlight : Monitoring set up of robotic arm for RR Doorsill Run@Rate
Figure 12 : Installation and programming of robotic arm by KUKA
Summary: The monitoring setup for RR Doorsill Run@Rate involves overseeing the programming and operation of a robotic arm by an engineer from Kuka Sdn Bhd. The robotic arm is programmed sequentially to execute a series of coded instructions for picking up plastic parts from the mold's core side using suction cups. This process ensures the efficient and gentle removal of plastic parts from the mold during injection molding processes.
Knowledge Gain: This task provides valuable insights into the automation and programming aspects of injection molding processes, specifically the utilization of robotic arms for part removal. Understanding the sequential coding, degree of freedom, and the vacuum-based gripping mechanism enhances knowledge regarding the advanced technologies involved in modern manufacturing.
Challenges and How to Overcome: One potential challenge in monitoring the setup is ensuring the precise and error-free programming of the robotic arm. To overcome this, close collaboration with the engineer from Kuka Sdn Bhd is essential. Regular communication and feedback loops during the programming phase help identify and address any issues promptly. Additionally, thorough testing and simulation of the robotic arm's movements can mitigate the risk of errors during actual operation.
WEEK 9
Weekly Activity Highlight : Enter Proton Shah Alam R&D Facility for Appearance Approval Report (AAR) event of PANEL TAILGATE OTR TRM part.
Figure 13 : AAR sample presentation at Proton Shah Alam R&D Facility
Summary: Entering Proton Shah Alam R&D Facility for the Appearance Approval Report (AAR) event of the PANEL TAILGATE OTR TRM part signifies a crucial stage in quality control, focusing on the visual aspects of the automotive component during mass production. The AAR establishes acceptable limits for gloss, color accuracy, and defect levels, ensuring the PANEL TAILGATE OTR TRM meets rigorous standards, contributing to the overall aesthetic quality of the vehicle.
Knowledge Gain: Participating in the AAR event provides insights into the meticulous criteria applied to assess appearance attributes. Understanding the significance of gloss, color accuracy, and defect levels in visible automotive components enhances knowledge of quality control measures specific to components with a direct impact on customer perception.
Challenges and How to Overcome: One potential challenge in the AAR process could be the subjective nature of aesthetic evaluation. To overcome this, collaboration and communication between the involved teams, including design, production, and quality control, are essential. Clearly defined standards and regular calibration sessions can help align perspectives and ensure consistency in the assessment of appearance attributes.
WEEK 10
Weekly Activity Highlight : MARii CATIA Certification Programme
Figure 14 : CATIA Design Configuration practice
Figure 15 : Group Picture of all staff and trainee of MARii CATIA Certification Programme
Summary: The examination focused on assessing proficiency in assembly principles using CATIA, covering components' connections, constraints, accurate alignment, drafting, Degree of Freedom, center of gravity, and part clash analysis. The successful outcome reflects dedicated preparation, practical sessions, and commitment to mastering assembly concepts, resulting in the attainment of the Assembly Design Associate certificate in CATIA.
Knowledge Gain: The examination process enhanced understanding and application of key assembly principles within a simulated environment. It validated the acquired knowledge in CATIA, emphasizing the importance of precision and efficiency in automotive design. Additionally, the certification underscores proficiency in 3D modeling, assembly design, and simulation.
Challenges and How to Overcome: The challenge in the examination lay in the comprehensive evaluation of various assembly concepts. Overcoming this involved systematic preparation, consistent practice, and a focus on understanding the intricacies of CATIA. Engaging in hands-on exercises and seeking clarification on complex topics helped in addressing challenges and ensuring readiness for the exam.
WEEK 11
Weekly Activity Highlight : Presentation for Faculty Supervisor visit to AHP Shah Alam
Figure 16 : Dr. Wan Aliff Bin Abdul Saad visit to Azman Hamzah Plastik Sdn Bhd
Summary: The presentation conducted for the visit of Dr. Wan Aliff, the faculty supervisor, at AHP Shah Alam's meeting room was a comprehensive overview of the intern's experiences in the automotive industry. It aimed to align the practical aspects of the internship with academic objectives, providing insights into projects, achievements, and challenges faced during the internship.
Knowledge Gain: The presentation offered an opportunity to showcase the practical applications of academic knowledge in a real-world automotive setting. It allowed the intern to delve into specific projects, detailing contributions, problem-solving initiatives, and collaborative efforts within AHP Shah Alam. The experience enhanced understanding of the dynamics of the automotive industry and the practical implications of theoretical concepts.
Challenges and How to Overcome: Discussing challenges openly during the presentation provided a platform for reflection and learning. By openly addressing the challenges faced, the intern demonstrated a proactive approach to problem-solving and an ability to extract valuable learning from difficult situations. The emphasis on learning opportunities within challenges contributed to the overall positive impact of the presentation.
WEEK 12
Weekly Activity Highlight : 4M Readiness preparation meeting
Summary: The Project Meeting for 4M (Men, Material, Machine, Method) Readiness for the mass production of Proton SS-11 is a pivotal gathering that involves a comprehensive evaluation and preparation for the shift from trial production to full-scale manufacturing. The 4M framework focuses on four critical elements: Men, Material, Machine, and Method, ensuring that each aspect is adequately prepared to meet the demands of mass production.
Knowledge Gain: Participating in such a meeting provides valuable insights into the intricacies of transitioning from trial production to mass manufacturing. It involves understanding the coordination and readiness required in terms of human resources, raw materials, production equipment, and manufacturing processes. This knowledge is crucial for the intern's understanding of the complexities involved in scaling up production.
Challenges and How to Overcome: The challenges in such a meeting may include identifying potential gaps or inadequacies in any of the 4M elements that could hinder a smooth transition to mass production. Overcoming these challenges involves proactive problem-solving and collaboration among different departments. Ensuring open communication channels and addressing identified issues through strategic planning and allocation of resources are key to overcoming challenges.