Intern Molding at Glasfil Polymer PDF

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COLLEGE OF ENGINEERING UNIVERSITI TENAGA NASIONAL

INDUSTRIAL TRAINING REPORT AT GLASFIL POLYMER SDN.BHD

NAME : DINESHWARAN CHANDIRA SEAGARAN STUDENT ID : ME 0102523 PROGRAMME : BME SEMESTER : SPECIAL YEAR : 2019/2020

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Table of Contents Acknowledgment

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1.0 Introduction

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1.1 Company Profile

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1.2 Company Logo, Vision, Mission

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1.3 Company Background

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1.4 Company Structure

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1.5 Student Duties

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1.6 Job Responsibilities

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2.0 On-Job-Training (OJT)

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2.1 OJT Admin

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2.2 OJT HR

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2.3 OJT M&E

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2.4 OJT Packaging

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2.5 OJT Purchasing

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2.6 OJT QA

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2.7 OJT Safety

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2.8 OJT Warehouse

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2.9 OJT Production

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3.0 Experience gain

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3.1 Injection Moulding Machine

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3.2 Mould Maintenance and Repair

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3.3 Learn and became expert in forklift

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3.4 Injection Moulding Machine

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3.5 Health and environment issue

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3.6 Safety aspects

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3.7 Problem encountered

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4.0 Finding and recommendations

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4.1 Conclusion

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4.2 Recommendations

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5.0 References

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Appendices

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Acknowledgement

First and foremost, I would like to thank Glasfil Polymer for giving me the opportunity to undergo my industrial training . The internship opportunity I had with Glasfil Polymer was a great chance for my learning and professional development. I am also grateful for having the chance to meet so many wonderful people and professionals who led me throughout this internship period. I would like to express a special gratitude to my mentor, Mr. Faizal Senior supervisor M&E from Glasfil Polymer who in spite of being busy with their duties, willingly spent their time out to guide, giving ideas for my project, give necessary advices and encouragement to me during my training. My supervisor also taught me on working ethics in aspect of punctuality and also disciplinary. I would also like to extend my appreciation to all engineers, staffs, technicians and trainees working at Glasfil Polymer for their kindness helping and supporting me through the entire industrial training program in Glasfil polymer. I would also like to thank Madam Samantha the boss of Glasfil Polymer who continue guiding us and understanding all employee situation during the mco period.

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1.0 Introduction

Abstract As competition for graduate jobs increases, students need to think of new ways to set themselves apart from all of the other equally qualified and skilled candidates. Graduates who have relevant workplace experience tend to be more valued by employers, and this makes internships an attractive prospect. An internship is an opportunity offered by an employer to potential employees, called interns, to work at a firm for a fixed period of time. Interns are usually undergraduates or students, and most internships last between a month and three months. Industrial training is a compulsory course as per required by all students in to undergo in order to pursue their degree in UNITEN. The minimum duration of this training is twelve (12) weeks. Students must complete a minimum of 70 credit hours and has a minimum CGPA of 2.0 at the time of registration. During the duration of training, students are expected to be exposed to various aspects of industrial practices and ethics and appreciate the significance of theoretical knowledge learnt in UNITEN into the real-life engineering practices. I as a student under Department of Mechanical Engineering, College of Engineering, Universiti Tenaga Nasional has successfully completed my training at Glasfil Polymer from 24th Feb 2020 to 20th Jun 2020 with a total duration of 17 weeks. My training in Glasfil polymer has been a wonderful experience for me because I am not only exposed to real life practice in Mechanical Engineering, but also some other field such as Electrical Engineering, Safety and Health and also technical skills such as maintenance policy which is the most essential knowledge as a Mechanical Engineering student.

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1.1 Company Profile

Since 1992, Glasfil Polymer Sdn. Bhd. specializing in Plastic Injection Molding with Mold Fabrication and Plastic Production. Our office with build-in factory located at Balakong, Selangor. Owned a high technology machine and experience system expert, show a big impact on production. With its 25 years experienced in the plastic industry, our expert knowledge, competence and reliability continue success in producing plastic product. As one of the leading manufacturers in Malaysia. Glasfil Polymer offer customers a one stop solution for mold fabrication and plastic injection. Our in-house design and tooling expertise provide professional part design and drawing according to the most exacting specifications. We do in-house trial and submit samples for customer’s approval to maintain our top-quality assurance. By achieving ISO 9001: 2015 certified status in year 2017, Glasfil Polymer becoming aware of the own corporate process and activity in each product within the scope of certification that help to identify continuously potential for improvement of the company. We promise the quality of the product will be either perfection or masterpiece for our customer and meet all the requirement needed.

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1.2 Company Logo, Vision & Mission

1.2.1 Company’s Logo

1.2.2 Company’s Vision Glasfil group - To create value in what we do and make a difference.

1.2.3 Company’s Mision Glasfil group – To be the industry leader in what we do and drive positive changes around us.

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Glasfil Values

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Branding -

Promote company’s products and services

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Uphold company’s branding and status

Great place to work -

Open door and direct policy

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Team work, respect and trust each other

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Make it easy to work with us

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Contribute to our communities worldwide

Career Focus and Results orientation -

Focus on results

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Assume responsibility

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Confront and solve problems

Creativity -

Dare to propose any kind of new ideas

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Praise for any new ideas

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Brainstorm ideas

Discipline -

Work integrity

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Achieve commitments

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Protect intellectual properties

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1.3 Company background

Glasfil Polymer Constantly improving and upgrading our production technology and at the same time educating our staffs to fulfill the customer’s demand and becoming the trusted manufacturer. In future, we will implement integrated operation with multiple technologies and be the “one stop centre” for plastic products market to fulfill diverse customers requirements. Thus, Glasfil Polymer will be able to offer customers with products that exceed their expectations. We serve original equipment manufacturers across multiple industries. Our current productions are a series of automotive, furniture accessories, telecommunication, automation, bathroom parts, electronics and electrical. Glasfil Polymer capable to navigate our aspiration to be recognized as the reliable polymer designer and supplier for plastic products in the global market place, we began to exported our product directly to Singapore and Germany and to USA, Australia and other countries indirectly.

MAIN BUSINESS ACTIVITIES

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ISO 9001 : 2015 manufacturing

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Mold fabrication/tooling c/w design and analysis Plastic injection molding with Video Non-Contact Measuring Device ( Accuracy ± 3 micron)

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Expertise in plastic material recommendation / consultation

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Material design with 2D and 3D Solidworks in plastic which includes Strength

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Analysis, Production Stimulation, Structural Strength and Pressure Resistance Provide secondary process such as Ultrasonic Welding, Pad Printing, Silk Screen

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and Assembly Jobs Manufacturing company which comply to Green Environmental System

Company achievements

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2007 – pbt black tube Problem : Customer have face problems with part breaking and current leaking. Solution : We have developed a special compounded PBT material with Glass Fiber to strengthen the functionality of the tubes. Advantage : The material we developed can stand high temperature up to 200° C and at the same time it maintain its rigidity. Disadvantage : The initial material used supplied from Taiwan. However, it failed the Heat Deflection Temperature and Hardness Test. Duration : It takes us two months before we succeed.

2010 – PP Diamond clip

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Problem : PP Diamond Clip when sent to overseas, it always experienced breaking when glass being inserted and always ended up rejected and returned in container. It also has colorfaded, weathering problems. Solution : First of all, we eliminate the use of PP Homo as a base for formulation and we adopt PP Copo. We add in special additives to impart softness, but at the same time, it remains rigid. UV Stabilizer and Antioxidant are added in to prevent parts from color fading. Quality Check : The Diamond PP Clip were sent to Singapore Laboratory for weathering and ageing test continuously for 3 months . It passes all the test. The parts now are being used in places like Australia for many years without complaint and rejects.

2012 – Water meter housing

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Problem : The Water Meter Housing was the most challenging project for us. This part required a lot of study and research.We started doing fabrication after we completely done all the research, analysis and simulation. Solution : We work closely with customer in order to have an excellent outcome as required. Finally, after it passes all the tests, the part being approved for application. We are so proud that this part being manufactured and produced here in Malaysia and eventually it will replace the existing parts manufactured in South Africa due to quality issue.

1.4 Company Structure Company location : 11

 2 manufacturing plant  1 warehouse  Distance to port klang : 50 KM  Distance to KLIA : 45 KM] Capacity :  19 machine ( 100 ton – 560 ton ) Additional capability  Gas assisted injection molding  Run 24/7 7 days/wk 2 shifts  80 employees  Current capacity: 60 – 70 %

Address: 19, Jalan Taming P/1, Off Lebuh Taming,, Taman Taming Jaya, 43300 Balakong, Selangor

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1.5 Student duties

1. Assists in day to day tasks It’s almost a guarantee you’ll be taking memos, maintaining files, organising, sorting, creating PowerPoint presentations, drafting reports. 2. Learn and gain experiences Hard skills are the technical skills you need to carry out your intern responsibilities, and eventually job duties, successfully. Examples include learning how to operate a computer program, drafting a company report, handling the company inventory, and maintaining the company database. 3. Learn to operate machines Skills like operating machine in the company is the best skills one can learn in a company. How the machine working and efficiency in producing the output. You can also learn about the defects and the effective ways to solve the problem as an engineer. 4. Learn to organise Suggesting ideas on how to organise the packed items accordingly and create a special place to store the items in order to deal the tasks more efficiently and on time.

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1.6 Job responsibility Week

Responsibilities  Report duty at Glasfil polymer 

Introduction on duties in Glasfil polymer

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Documentation checking for internship students.

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Meet up with trainers to set an appointment for On-Job-Training (OJT).

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Assigned to M&E department.

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Attended OJT meetings on Admin, Compounding (IETS), Compounding, HR, M&E, Packing, Production, Purchasing, QA, Safety, and Warehouse.

1st & 2nd week

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Made reports on the attended OJT meetings.

(25 Feb – 9 Mar)

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Meet up with supervisor, Mr Faizal and discussed on project tittles.

3rd – 7th week

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Became a expert in servicing mold. Meeting with the General Manager, Madam Sam

(11 Mar – 7 Apr)

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Made company plans.

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Went to a few lines that were down line for maintenance work.

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Had a discussion with supervisor followed by managing director.

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Had to work from home due to the Corona Virus pandemic.

8th -12th week

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Did a research on products can be update in future. Work from home due to mco.

(15 Apr – 15

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Updated production planning in excel

May)

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Draw a product by using autocad.

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Did a research on the use of biopolymer.

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Compare between polymer and biopolymer.

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Presented it to my company managing director.

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Did another research on injection molding defects and ways to

13th -16th week

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solve it Resume my intern as company orders.

(15 May – 20 june)

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Worked at production line managing the machine, stock and etc.

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Help with production calculations.

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2.0

On-Job-Training (OJT)

Glasfil polymer requires all their employees including trainees to complete the On-JobTraining while working in the factory. OJT helps develop the career of the individual and the prosperous growth of the organization. On the job training is a form of training provided at the workplace. During the training, employees are familiarized with the working environment

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they will become part of. Employees also get a hands-on experience using machinery, equipment, tools, materials, etc. Part of on-the-job training is to face the challenges that occur during the performance of the job. An experienced employee or manager is executing the role of the mentor who through written or verbal instructions and demonstrations are passing on his/her knowledge and company-specific skills to the new employee.

2.1 OJT Admin

 Registered finger scan and signed all the necessary documents.

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 Short briefing on how the finger scanner works.

 Getting to know the break times provided.

 Briefing on the bank account and allowance.

 Requested for an email under glasfil polymer.

 Briefing on the DWR responsibilities.

 Briefing on the Monthly Suggestions procedure.

 Briefing on the various spot checks.

 Briefing on the Factory and the safety regulations, department & Management Meetings (IDM).  Briefing on annual company meetings.

2.2 OJT HR

 Glasfil polymer prioritizes foreign workers and focuses on their passport and permit.

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 Workers bond with contract and also hired by agent.  If worker wants to go back before their contract ends, they must provide valid reason.  Company will hired new staff time to time.  Hostel is provided if the worker is leaving more than 40 km away and the worker must abide by the rules of the hostel.  The food and drinks sold in the canteen are monitored by HR and workers must use the cutleries provided for hygiene purposes.  Monthly sports even will be held and the admission is free for all workers, staff, and trainees.  There is also fruit distribution on every third Wednesday of the month. The fruit distributed will either be an apple or an orange.  A dental kit will also be provided yearly to encourage oral hygiene.

2.3 OJT M&E

 There are three main utilities at M&E department which are water, gas, and electricity.

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a) Water is supplied by SYABAS (Jabatan Bekalan Air) throughout the whole factory for the production line and other daily uses. b) Gas is supplied by GMB (Gas Malaysia Berhad) and used for the oven burner and canteen. The gas supplied is methane, a type of natural gas. The gas pipes are indicated with the color yellow. c) Electricity is supplied by TNB (Tenaga Nasional Berhad) is 11kW which the will go through a step down transformer before being supplied to kilang 1 and kilang 2.  The highest expenditure on utilities is on gas.  There are four divisions for M&E department : a) Mechanical – Mechanical work and maintenance b) Electrical – Electrical related maintenance c) Burner – Piping issues throughout the factory. d) Forklift & Air compressor – Service for forklift and service compressor

M&E Department handles the maintenance related to mechanical and electrical. Fix any breakdown or where and trace the issues. Mostly this works done by our supervisor since they are capable of solving the issues.

2.4 OJT Packing

 Learned types of packaging materials such as carton and sugar bag.

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 Online packer are people who immediately packed the products once it has been produced and follow the number of products wanted by the customer.  Marketing department will take order from customer through customer request form.  Rejected products will be back to the company to reuse the material and reproduce another product.  The brand of the box must match the carton.  QA department will take sample once the products are prepared to ensure it is completely ready to be shipped.

2.5 OJT Purchasing

 Purchaser is the middle person.

User

Purchaser

Supplier 23

 Two categories of PR: a) Catalog item – all details are given b) Ad hoc item – Customizable by customer  LOC, Letter of Complaint can be summited if the supplier damaged anything or misbehave. This is to ensure that the supplier does their job.

 Store item will be monitored and must be used within 60 days.  Non-store item is not monitored but it’s made sure to be at optimum quantity.

2.6 OJT QA

 There are four categories:

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a) MQC – Material Quality control b) PMQC – Purchasing Material c) IPQC – In process d) PQC – Product quality control  Type of test: a) Water tight test

Four defect category:

a) Critical defect b) Freedom from holes c) Major visual d) Minor visual

2.7 OJT Safety

 The main concern of safety is to prevent accident and protect the workers.

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 All workers should follow PPE, Personal Protective Equipment.

 If there are any a...