Week 1
Report to work and having a short briefing with HR manager. Get to know the background of the company, status of company, policy and confidential. Meet with supervisor and knowing the job scope. Have the opportunity to enter the ESD and 1K clean room and involving in sample build up. In this area, there are some SOP that need to follow and make sure that wearing full PPE before entering this area. Understanding the procedure in making the sample and all the process will be involved. I am learning and trying to understand the drawing given by the customer before assisting my supervisor in making the sample.
Week 4
Learning to mix the silicone gel which is mixing the Part A and Part B in equal portion. Then, pouring it into the housing before moulding. Besides, I also learning to rework of the rejected cable which required to clean the silicone gel then trim the length of the cable. After that, solder the cable to the housing again follow the wiring diagram in the drawing. Assisting in doing the new project which need the high skills of soldering.
Week 7
Using the buzzer to test for the same wire then label the same wire. Insert the wire to the housing or connector correctly according to the wiring diagram. Did the sample wrongly which I did not realize that there is a wire number printed on the wire. However, this issue is solved and I have learned from this mistake and will not make the same mistake again next time. Doing the label of the sample then double checking of the label paste on the cable sample.
Week 10
Dr. Ikmal coming for industrial visit and internship assessment. Presentation of industrial training progress is done. My task this week is generally changing of the heat shrink tube of the sample as the original heat shrink tube is too big and there is a gap between the cable and the tube. It needs to shrink two to three layers of the heat shrink tube in order to prevent the water entering the housing when customer install it in their machine or product. Then, learning to create a test for the sample by setting the HIPOT testing parameter.
Week 2
Learning to understand the drawing that covers the bill of material, dimension with tolerance and ways to assemble the product. The processes involve are basically cutting tube, shrink the heat shrink tube, installing the expandable braided sleeving. Assisting my supervisor to do for the tube sample. Doing the inspection of the tube sample before sending for cleaning. Cleaning the sample under the UV light and isopropyl alcohol. Making sure that there is no dust on the sample then seal it. I had changed to a new workplace which is the sample room.
Week 5
Learning to do moulding of the cable sample. This needs to choose the correct mould and install the mould in the injection moulding machine before moulding. It is important to make sure that the temperature of the injection moulding machine is high so that the moulding on the cable is perfect with no dull surface. After the moulding is done, testing of the cable sample is required. Moreover, I also able to gain knowledge on the sandblasting using aluminium oxide and the powder coating process.
Week 8
Learning to use the laser print to print the text on the white heat shrink tube. It needs to set and adjust the text so that it can print nicely on the heat shrink tube. Then, shrink the label on the wire respectively according to the drawing. Make sure that all the text of the label is correct as well as the position of the label. Besides, the sample also required to crimp the ferrule by using the crimping machine. The other sample that has done is the power plug sample. Try and learn to do for the power plug sample.
Week 11
Learning to operate the wire cutting machine by setting the blade function and the length required for cutting. After setting the parameter, cut five pieces for testing and checking under the scope. Make sure that the blade does not hurt the conductor of the wire. Besides, I also required to check and inspect for the crimped part of the brown wire. Reject the wire if the jacket of the wire is not crimped or the wire is not crimped fully. Next, I also able to learn and understand the basic on the tensile testing of the crimped wire.
Week 3
Changing of new supervisor. Learning the skill of crimping and soldering. Understand the basic skills of soldering as the sample is required to solder the cable to the housing. After soldering, it is required to clean the flux residual using flux removal before filling the silicone gel into the housing. Besides, the sample also required for crimping the terminal. After done the sample, HIPOT testing is required in order to make sure that the cable sample is in good condition and can function well.
Week 6
Learning to do stripping of the wire by using the stripping machine. Adjust the blade of the machine according to the diameter and AWG of the wire. Besides, the jacket strip length is also in the consideration of the adjustment of blade. Gain knowledge on making a jumper then solder it to the adapter. After done a sample, all the process and the measurement involved are jot down as a record of work instruction. Get to know and understand the basic skill of tinning.
Week 9
Learning the way to pack the finished sample that are ready to ship to the customer. Pasting the label which contains the information such as the purchase order number and the description of the sample on the plastic bag for each finished sample. Besides, continue to do for the other sample that are required to make a jumper, install the expandable braided sleeving and do for the housing insertion. Other than that, learning to add the instruction and set the parameter in order to test the cable sample.
Week 12
Learning to do for the new power plug sample. It is required to screw the wire according to the colour to the plug. Then, crimping the ferrule on the wire of the other end of the power plug sample. After the sample is done, do for the testing of the plug. Besides, learning to use IMAJE printer to print the label on the hear shrink tube. Then shrink the label on the wire. The other task is to do for the Ethernet cable which required to insert the wire based on the colour and then crimp the RJ45 connector. This is the last week of intern and I required to hand over the project to my colleagues.