Intership at Honda Manufacturing Sdn Bhd

Date/Day         : 11 June 2018 – Monday

Weather           : Morning – Sunny, Evening – Cloudy

Project             : -

Activity           :

Registeration for Practical Trainee Conducted by Pn Nurul Huda Binti Abdul Rasid (Human Resource)

• Various forms filling session such as details, emergency contacts, university internship coordinator.
• Honda official uniform, safety shoe, cap distribution to practical trainee.
• Bank statement, identity card photocopy, passport photo submission to Pn Huda.

Briefing on HMSB and HASB Conducted by Pn Nurul Huda Binti Abdul Rasid (Human Resource)

• Induction Training Booklet distribution as guideline for practical trainees.
• Briefing included on Honda Philosophy, work enviroment, job scope, internship objectives from Honda, minor/major misconducts explainations, security, rules and regulations and safety and health.
• Department distribution for trainees.
• Been assigned to be at Welding 02 department for the whole internship.
• Meet and Greet session between trainee and staff at Welding 02 department.

Date/Day         : 12 June 2018 – Tuesday

Weather           : Morning – Sunny, Evening – Sunny

Project             : -

Activity           :

• Depart from home at 7.00am.
• Reach the factory at 7.15am. Report at organization/ company.
• Joined 'taiso' session at Welding 02 department at 7.40am.

• Welding 02 work division Briefing by Pn. Fatimah (Quantity Surveyor)

1.  Lead by CIE En. Fitri, and under him there is Quality Check (QC) lead by En. Akmal, Quantity Surveyor lead by Pn. Fatimah and Engineering Improvement (EI) lead by En. Azli.
2.  Assigned to be under Pn. Fatimah (QS) for two weeks.

• Tasks need to be done: 

1. Audit will be done at 27 June 2018 according to ISO 9001:2015 (Risk).
2. Been assigned to help in updating the Monthly Check Sheet Tracking List (as shown in the picture below).

• Check either the documents/data check sheet below available or not starting from January to May:

1. Daily Production Report.
2. Hourly Production Report (GW).
3. Hourly Production Report (ZoneC).
4. Hourly Production Report (QC).
5. White Body Fitting Inspection.
6. White Body Inspection Appearance Check RHS.

Date/Day         : 13 June 2018 – Wednesday

Weather           : Morning – Sunny, Evening – Rainy

Project             : -

Activity           :

• Depart from home at 7.00am.
• Reach the factory at 7.15am. Report at organization/ company.
• Joined 'taiso' session at Welding 02 department at 7.40am.
• Continue updating document, for document no. 6-10 (as below):

1. White Body Fitting Inspection.
2. White Body Inspection Appearance Check RHS.
3. White Body Inspection Appearance Check LHS.
4. White Body Inspection Appearance Buy Off
5. Torque Wrench Inspection (Fitting).
6. LQ Line Monitoring Check Sheet.

• Summarization on total number of missing check sheet that been sorted by month (January-May) for documents no. 1-5 only.
• Go home at 5.40 pm.

Hari Raya Leave (Factory Shutdown 14-20/6)

• Depart from home at 7.00am.
• Reach the factory at 7.15am. Report at organization/ company.
• Joined 'taiso' session at Welding 02 department at 7.40am.

• Welding Fundamental Briefing by En Akmal (QC).

1. Welding for automotive using spot welding, MAG welding, welding wire.
2. Resistance (Car Plate) is put between positive terminal gun and negative terminal gun.
3. The metal of car plate melted then both bath combined by the metal melted.
4. Welding for automotive have control item that needed to be concern during welding process been carried out, such as:

• Electric
• Pressure 
• Electrode

• Operation Standard (OPS) of Side Panel Component RHS/LHS and Outside Panel Component RHS/LHS explaination.

1. Spot welding QC referring to the diagram of weld spots that included in the OPS.
2. Defects detection such as crack, blow hole, burr/sharp edge and pin hole.
3. Nugget diameter must be 4-7mm.
4. Side Panel Component RHS/LHS weld spot total are 56 while Outside Panel Component RHS/LHS.
5. Control item (Outside) includes:

• Weld strength (stickiness)
• Weld appearance
• Weld spot number
• Weld spot location
• Strengthen of spot weld condition
• Weld strength
• Sealant application (Side only)

• Go home at 5.40 pm

• Depart from home at 7.00am.
• Reach the factory at 7.15am. Report at organization/ company.
• Joined 'taiso' session at Welding 02 department at 7.40am.
• Logbook supervisor signature request for first week report.
• Practising 5S at 10 years document lockers.
• NAC Meeting at 5.00 pm. Crisis story review by Production Line 1 and 2 Manager.
• Go home at 6.15 pm.

• Sick leave due to back spinal pain.

• Depart from home at 7.00am.
• Reach the factory at 7.15am. Report at organization/ company.
• Joined 'taiso' session at Welding 02 department at 7.40am.
• 5S Session at Welding 02 Department's smoking area.
• Check and update 'WE CURRENT OUTPUT AND PRESSURE CHECK SHEET' mainly focused on transformer and gun availibility for three car model (City, Jazz, HRV).
• Helping in documentation of new Operating Standard (OPS) for Welding 02 department for zone A,B and C.
• Due to audit day that will be held tomorrow (27/6).
• Helping Head Of Department (HOD) Shahir in preparing Skill Olympic Item Status Table.
• Go home at 5.45 pm.

• Depart from home at 7.00am.
• Reach the factory at 7.15am. Report at organization/ company.
• Joined 'taiso' session at Welding 02 department at 7.40am.
• Helping in updating monthly check sheet tracking list for February, March and April.
• Helping in documentation of new Operating Standard (OPS) for A, B, C of welding department.

• Helping Head Of Department (HOD), En Syahir Bin Razali in preparing Skill Olympic Game for ATAI itinerary that includes: 

1. Sports Olympic Game for ATAI Itinerary.

•  The 9th Asia Ocenia Welding Bukai Skill Olympic will be held from 16 July 2018 until 20 July 2018 at Honda Manufacturing Sdn Bhd, Durian Tunggal, Melaka.
• This event involving few countries that are:

1. Indonesia Honda Prospect Motor (HPM).
2. Honda Cars Philippines Inc. (HCPI).
3. Thailand Honda Automobile Co. (HATC).
4. Honda Manufacturing Sdn Bhd Malaysia (HMSB). *HOST COUNTRY
5. Honda Vietnam (HVN).
6. Honda Taiwan (HTW).
7. Honda Atlas Cars Pakistan Limited (HACPL).
8. Honda Cars India Ltd. (HCIL).

• Each countries will participate in 4 types of game that are:

1. Spot Weld Game.
2. Deform Game.
3. MIG Individual Game.
4. MIG Group Game.

• Go home at 5.45 pm.

• Depart from home at 7.00am.
• Reach the factory at 7.15am. Report at organization/ company.
• Joined 'taiso' session at Welding 02 department at 7.40am.
• Preparing opening ceremony flow for The 9th Asia Ocenia Welding Bukai Skill Olympic for Head of Department (HOD) En Syahir bin Razali

Figure 1: Opening Ceremony Event Itinerary

• Helping in documentation of new Operating Standard (OPS) for HRV Car Model according to its zone, A, B and C.
• Helping in disposal of old Operating Standard (OPS) for HRV Car Model.
• Preparing judgement method for The 9th Asia Ocenia Welding Bukai Skill Olympic for Head of Department (HOD) En Syahir bin Razali for Sample Batch 1st, Option 1 and Option 2 includes evaluation item and marks allocation detailed.

Figure 2: Judgement Method and Sample Batch 1st.

Figure 3: Judgement Method (MIG) Option 1.

Figure 4: Judgement Method (MIG) Option 2.

• Fire drill at 5.00 pm for the whole Honda Manufacturing Sdn Bhd and Honda Assembly Sdn Bhd.
• Go home at 6.00 pm.

• Depart from home at 7.00am.
• Reach the factory at 7.15am. Report at organization/ company.
• Joined 'taiso' session at Welding 02 department at 7.40am.
• Preparing Judges Division slide for HOD Mr. Syahir Fahmi Bin Razali.

Figure 1: Judges Division

• Improvement on judgement method slides for four type of Skills Olympic Games (MIG, Spot, Deform, F-1), as shown below:

Figure 2: Judgement Method (MIG)

Figure 3: Judgement Method (Spot)

Figure 4: Judgement Method (Deform)

Figure 5: Judgement Method (F-1)

• Go home at 5.40 pm.

• Depart from home at 7.00am.
• Reach the factory at 7.15am. Report at organization/ company.
• Joined 'taiso' session at Welding 02 department at 7.40am.
• Improvising judgement slide as shown below:

Figure 1: Countries Participate Division

• Being tasked to inspect and fill-up Nugget Diameter Check Sheet for zone B. Here are things that needed to be considered before start filling up the check sheet:

1. Fill according to it shift, A (7.40 am - 5.30 pm) and B (7.40 pm - 5.30 am).
2. Then, by zone, A or B. For zone C and quality check zone there is no nugget diameter to be measure thus no check sheet to be filled up.
3. Then, before starts measuring the diameter of nugget, inspector must make sure that  the transformer and gun number are correct to ensure the test piece that needed to be measured is from the correct gun and transformer and also with the correct process.
4. There are about 31 guns use in zone B welding production line for various processes, so there are 31 nugget diameter check sheet that needed to be filled up.
5. Then, check either the gun (equipment) use either spot, bolt stud or stationonary.

Figure 2: Nugget Diameter Check Sheet.

• There are two type of gun, C-type and X-type. Both are use in each processes according to its own Operating Standard (OPS).
• Test piece- a piece of metal sheet that been used for measuring nugget diameter after gun been test run on the piece.
• There are two type of test piece that been used, 3 metal sheet  and 2 metal sheet test piece.

Figure 3: Test piece for 2 metal sheet.

• The test piece must be obtained from each process at its own workcell.
• The test piece is place at test piece holder that located at each workcell.

Figure 4: Gun Stand and Test Piece Holder.

• Steps to check nugget diameter:

1. Measure diameter A and B.
2. Then, calculate diameter nugget by adding diameter A and B then divide it by 2.
3. Repeat the steps 1 and 2 for interval of 1, 15, 30, 45, 60, 75, 90, 105 (number of production).
4. Fill the data based on day, model that runs on that particular day.
5. Nugget diameter must follow standard nugget diameter that are 4- 7 mm.
6. If the nugget diameter below the standard nugget diameter 'abnormal flow' must be follow because it is consider as NG.
7. If it following standard nugget diameter then the process can be continue normally.

• Abnormal Flow:

            Associate --> T/L Prod --> T/L Equality --> Engineer --> Assistant Manager --> Manager

Figure 7: Test piece holder.

• Test piece holder are divided into four section according to the model.
• For green colour section the test piece is for Honda City.
• For purple colour section the test piece is for Honda BR-V.
• For yellow colour section the test piece is for Honda HR-V.
• For blue colour section the test piece is for Honda Jazz.

• Final check on any error or miscalculation during nugget diameter check sheet data collecting.
• Go home at 5.50 pm.

• Depart from home at 7.00am.
• Reach the factory at 7.15am. Report at organization/ company.
• Joined 'taiso' session at Welding 02 department at 7.40am.
• Improvement on Judge Fundamental Flow slides, according to contests.

Figure 1: Judgement Fundamental Flow (MIG).

Figure 2: Judgement Fundamental Flow (Spot).

Figure 3: Judgement Fundamental Flow (Deform).

Figure 4: Judgement Fundamental Flow (F-1).

• Join QC Meeting with En Akmal.
• Meeting held to justify night shift issues that happened at 02th July 2018 (yesterday).
• Analysis done shows that issues occur due to:

1. History issue from process and department related.
2. Flow out from WE TUL due to feedback flow and stoppage.

• Action that been done today to overcome the issues are:

1. Discussion with production member on manpower allocation at TUL.
2. Improvement on LQ Line feedback flow and restructure manpower allocation.

Figure 5: Issues and Analysis Table.

Figure 6: CBU WE2 Outflow Prevention Mapping.

• Preparing Judges Sorting Steps for Skill Olympic event and proposing new judges sorting template.

Figure 7: Judges Sorting Steps Option 1.

Figure 8: Judges Sorting Steps Option 2.

Figure 9: Judges Sorting Steps Template.

• Go home at 5.40 pm.

• Depart from home at 7.00am.
• Reach the factory at 7.15am. Report at organization/ company.
• Joined 'taiso' session at Welding 02 department at 7.40am.
• Improvement on Judges Information Briefing slides for The 9thAsia Oceania Welding BukaiSkill Olympic HMSB Malaysia.

Figure 1: Judges Information Briefing Slides.

• Judges Information Briefing review with H.O.D, Mr Syahir Fahmi bin Razali.
• Joining spot weld contest simulation for The 9thAsia Oceania Welding BukaiSkill Olympic HMSB Malaysia.
• Been tasked to be one of the contest committee.
• Go home at 6.00 pm.

• Depart from home at 7.00am.
• Reach the factory at 7.15am. Report at organization/ company.
• Joined 'taiso' session at Welding 02 department at 7.40am.
• Improvement  and finalization of Judges Information Briefing slides.

Figure 1: Judges Information Briefing slides

Figure 2: Judges Information Briefing slides  (cont.)

• H.O.D Mr. Syahir bin Razali 3rd review for Judges Information Briefing slides
• Review feedback:

1. Needed to fix on judgement time allocation as some of the judgement may be done during the contest is running.
2. Needed to follow whole contest time.

• Accompanied En Akmal (QC Leader) to Vehicle Quality (VQ) Department due to unflush door issue of Honda Jazz back door.
• The door was unflush for about 0.3-0.5 mm thus not following the Operating Standard (OPS) of VQ Department.
• Issue cannot be resolved due to constraint of time (end of work time 5.40 pm) and will resume at tomorrow morning.

Figure 3: Inside view of Honda Jazz Back Door (Deviation)

Figure 4: Inside view of Honda Jazz Back Door (Standard Quality Check Requirement)

Figure 5: Inside view of Honda Jazz Back Door (Tolerance)

Figure 6: Outside view of Honda Jazz Back Door (Standard Qualiti Check Requirement)

• Go home at 5.40 pm.

• Depart from home at 7.00am.
• Reach the factory at 7.15am. Report at organization/ company.
• Joined 'taiso' session at Welding 02 department at 7.40am.
• HOD Mr Syahir 4th review on Judges Information Briefing slides.

Figure 1: Judges Information Briefing slides

Figure 2: Judges Information Briefing slides (cont.)

Figure 3: Judges Information Briefing slides (cont.)

Figure 4: Judges Information Briefing slides (cont.)

• The 9thAsia Oceania Welding Bukai Skill Olympic HMSB Malaysia committee meeting at 12.20 pm with Manager Mr. Hairrol. 
• Go home at 5.40 pm.

• Depart from home at 7.00am.
• Reach the factory at 7.15am. Report at organization/ company.
• Joined 'taiso' session at Welding 02 department at 7.40am.
• Preparing MIG Group Parameter Check Sheet for HOD Mr Syahir bin Razali.

Figure 1: MIG Group/F-1 Paramater Check Sheet

• Study on costs of quality.
• There are 4 type of cost of quality:

1. Prevention costs
2. Appraisal costs
3. Internal failure
4. External failure

• Go home at 5.40 pm.

• Depart from home at 7.00am.
• Reach the factory at 7.15am. Report at organization/ company.
• Joined 'taiso' session at Welding 02 department at 7.40 am.
• Self-learning process by walking around the production line.
• Some of new things that I learned are:

1. Smart GW section stand for Smart General Welding.
2. Jig changes according to the model that production is running.
3. Jig color as reference for each type of model that is running.
4. There are 4 colors that available, same concept as test piece holder color tagging.

• Involve in Skill Olympic Spot Contest rehearsal at training area at 3.40 pm.
• Go home at 5.40 pm.

• Depart from home at 7.00am.
• Reach the factory at 7.15am. Report at organization/ company.
• Joined 'taiso' session at Welding 02 department at 7.40 am.
• Helping En Mahadir in preparing steel hanger for 5S purpose of Skills Olympic Games at Welding Department 02
• Join Skills Olympic rehearsal at training centre for Deform Contest and MIG Group contest.
• Go home at 5.40 pm.

• Depart from home at 7.00am.
• Reach the factory at 7.15am. Report at organization/ company.
• Joined 'taiso' session at Welding 02 department at 7.40 am.
• Add-on Judge Score Format slide in Judges Information Briefing slides.
• Join rehearsal for MIG Group and Deform contest for Skills Olympic.
• Finalise of Judges Information Briefing slides.
• Divided Judges Information Briefing slides into Spot, Deform, MIG Individual, MIG Group.

Figure 1: Judges Information Briefing (Spot Contest)

Figure 2: Judges Information Briefing (Deform Contest)

Figure 3: Judges Information Briefing (MIG Individual Contest)

Figure 4: Judges Information Briefing (MIG Group Contest)

• Go home at 5.40 pm.

• Sick leave due to back pain problem and cough.

Date/Day         : 07 August 2018-Tuesday

Project             : Air Blower System

Activity           :

• Depart from home at 7.00am.
• Reach the factory at 7.15am. Report at organization/ company.
• Joined 'taiso' session at Welding 02 department at 7.40 am.
• Doing 5S around welding department due to visitors incoming.
• Joined and supporting production line at Zone A for the model of BRV until 3.00 pm.
• Continue in measuring process pressure at the air blower project place. The outcomes are:

1. Pressure for single hose input (another hose closed): 0.5 MPa

Figure 1: Reading for single hose input.

2. Pressure for double hose input: 0.1 MPa

Figure 2: Reading for double hose input.

• Brainstorming on how to increase pressure at the air input to get efficient blower system.
• Go home at 5.40 pm.

Date/Day         : 08 August 2018-Wednesday

Project             : -

Activity           :

• Depart from home at 7.00am.
• Reach the factory at 7.15am. Report at organization/ company.
• Joined 'taiso' session at Welding 02 department at 7.40 am.
• Doing 5S around welding department due to visitors incoming.
• Supporting Quality Line for inspection and controlling bumper hood issue and front lamp issue.
• Go home at 5.40 pm.

Date/Day         : 09 August 2018-Thursday

Project             : Air Blower System

Activity           :

• Depart from home at 7.00am.
• Reach the factory at 7.15am. Report at organization/ company.
• Joined 'taiso' session at Welding 02 department at 7.40 am.
• Brainstorming on how to increase pressure at air blower piping system.
• There are three main components that needed to be considered:

1. Flow , Pressure, Velocity (based on Bernoulli's principle)
2. Local pressure and cumulative pressure.
3. In pipe/hose constrain; long length hose, air forces through small openings, bends, nozzles.

• Supporting Quality Line for inspection and controlling bumper hood issue and front lamp issue.
• Go home at 5.40 pm.

Date/Day         : 10 August 2018-Friday

Project             : -

Activity           :

• Depart from home at 7.00am.
• Reach the factory at 7.15am. Report at organization/ company.
• Joined 'taiso' session at Welding 02 department at 7.40 am.
• Literature review on OSHA Terms related to metal dust clean up.
• Referring to OSHA 'Food and Grain, 2012' NCPA 654 (2013 Version) there  are 3 steps for housekeeping for industry are:

1. Use vacuum dust, grounded and bonded.
2. If vacuum cannot reach it, conduct a water wash.
3. Cleaning with compressed air is permissible only in small areas with operating equipment shut down.

• The project may needed for air blower may needed more time to enable it to be accomplished.
• Go home at 5.40 pm.

Date/Day         : 13 August 2018-Monday

Project             : -

Activity           :

• Depart from home at 7.00am.
• Reach the factory at 7.15am. Report at organization/ company.
• Joined 'taiso' session at Welding 02 department at 7.40 am.
• Supporting Zone C (Fitting/Finish) for tail gate installation for HRV model.
• Go home at 5.40 pm.

Date/Day         : 14 August 2018-Thursday

Project             : -

Activity           :

• Depart from home at 7.00am.
• Reach the factory at 7.15am. Report at organization/ company.
• Joined 'taiso' session at Welding 02 department at 7.40 am.
• Supporting Quality Line for inspection and controlling bumper hood issue and front lamp issue.
• Go home at 5.40 pm.

Medical leave due to back pain sickness.

Date/Day         : 16 August 2018-Thursday

Project             : Quality Database For WE, PA, AF, VQ Department

Activity           :

• Depart from home at 7.00am.
• Reach the factory at 7.15am. Report at organization/ company.
• Joined 'taiso' session at Welding 02 department at 7.40 am.
• Supporting Quality Line for inspection and controlling bumper hood issue and front lamp issue.
• Literature review on cloud database and pricing comparison between different cloud database storage.
• Go home at 5.40 pm.

Date/Day         : 17 August 2018-Friday

Project             : Quality Database For WE, PA, AF, VQ Department

Activity           :

• Depart from home at 7.00am.
• Reach the factory at 7.15am. Report at organization/ company.
• Joined 'taiso' session at Welding 02 department at 7.40 am.
• Literature review on cloud database and pricing comparison between different cloud database storage.
• Industrial training report preparation. 
• Go home at 5.40 pm.

Date/Day         : 20 August 2018-Monday

Project             : Quality Database For WE, PA, AF, VQ Department

Activity           :

• Depart from home at 7.00am.
• Reach the factory at 7.15am. Report at organization/ company.
• Joined 'taiso' session at Welding 02 department at 7.40 am.
• Literature review on cloud database vendors and pricing comparison between different cloud database storage.
• Slide preparation for quality database project.
• Industrial training report preparation. 
• Go home at 5.40 pm.

Date/Day         : 21 August 2018-Tuesday

Project             : Quality Database For WE, PA, AF, VQ Department

Activity           :

• Depart from home at 7.00am.
• Reach the factory at 7.15am. Report at organization/ company.
• Joined 'taiso' session at Welding 02 department at 7.40 am.
• Literature review on cloud database vendors and pricing comparison between different cloud database storage.
• Slide preparation for quality database project.

Figure 1: Quality Defects Database slides. 

• Industrial training report preparation. 
• Go home at 5.40 pm.

Hari Raya Aidil Adha leave.

Date/Day         : 24 August 2018-Friday

Project             : Quality Database For WE, PA, AF, VQ Department

Activity           :

• Depart from home at 7.00am.
• Reach the factory at 7.15am. Report at organization/ company.
• Joined 'taiso' session at Welding 02 department at 7.40 am.
• Literature review on cloud database vendors and pricing comparison between different cloud database storage.
• Slide preparation for quality database project.
• Industrial training report preparation. 
• Go home at 5.40 pm.

Date/Day         : 27 August 2018-Monday

Project             :

Activity           :

• Depart from home at 7.00am.
• Reach the factory at 7.15am. Report at organization/ company.
• Joined 'taiso' session at Welding 02 department at 7.40 am.
• Helping Pn Fatimah in preparing PBS Gate tagging for the issue of 1st  & 2nd Door Inside Still Dent.
• Slide preparation for quality database project.
• Industrial training report preparation. 
• Go home at 5.40 pm.

Date/Day         : 28 August 2018-Tuesday

Project             :

Activity           :

• Depart from home at 7.00am.
• Reach the factory at 7.15am. Report at organization/ company.
• Joined 'taiso' session at Welding 02 department at 7.40 am.
• Slide finalize for quality database project due to review at 2.00 pm with engineer from VQ Department Line 1.

Figure 1: Quality Defect Database Project slides.

Figure 2: Quality Defect Database Project slides (cont.)

Figure 3: Quality Defect Database Project slides (cont.)

• Feedback from the review is some items must be included in the slides to gain top management interest. The items that must be included are:

1. Assigned P.I.C from each departments.
2. Requirements of files/data that must be uploaded into the database.
3. Flowchart on how to insert data into database.
4. Purpose/Objectives of database project.
5. Track and Trace system in the database.
6. Required space.
7. Firm general concept.
8. Accessibility.
9. Highlights of database contributions towards FOKUBO.
10. File naming format.

• Brainstorming on feedback of review.
• Industrial training report preparation. 
• Go home at 5.40 pm.