Example Practical Report

CHAPTER 1 INTRODUCTION

1.1 OVERVIEW

Industrial

Training

KolejKemahiranTinggi

(INTRA)

MARA

is

one

of

the

&InstitutKemahiran

requirements MARA

for

students

all of

Diploma/Sijil Programmers. The industrial training supplements the student¶s academic education in engineering courses by exposing them to practical experience in an actual working environment; opening avenues for them to develop their skills and capabilities.

1.2 OBJECTIVES

Students will able to apply the skills that they have gained throughout their academic years. In addition, they can enhance their knowledge and abilities at the companies that they attached to.

This internship is also a shared social obligation for both KKTM and the practical companies involved. KKTM practical students will assist the companies in handling any related jobs and it also enables KKTM to identify industries¶ current needs, hence improving any weaknesses discovered. Therefore, The KKTM will be able to strengthen its curriculum and produce graduates who are market ready.

1

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1.3 INTRA DETAILS

SONY EMCS (M) SDN BHD Lot 5, JalanKemajuan, Bangi Industrial Estate, 43650 Bandar Baru Bangi, Selangor Darul Ehsan.

COMPANY NAME COMPANY ADDRES

CONTACT NO. OFFICE: FAX: DEPARTMENT ATTACHED COMPANY SUPERVISOR DESIGNATION

03 - 8925 7587 03 - 59252649 Television Quality Reassurance (TV QR) Mrs. MazlindaBinti Abdul Majid Senior Engineer

Table 1.0: INTRA Detail

1.4 POSITION GIVEN

The student was positioned at the TVQR department. In this department, the student was located under Product Safety (PS) group which conduct five type of testing like Realibility Incident Preventive Rule (RIPR), Leakage Current, Power Consumption, Fool Proof, and Smell Test & Outgas. As a trainee, student was put under smell test & outgas group.

1.5 DEPARTMENT ATTACHED

The student must report their progress to designated Company Supervisor. For this purpose, the student must report to Mrs. MazlindaBinti Abdul Majid. For KKTM Supervisor, the student must report to Sir Shahril.

1.6 TASKS

The major task that the student has to do in this department is to perform















CHAPTER 2 GENERAL PRESENTATION OF THE COMPANY

2.1 COMPANY PROFILE

Sony Corporation is a Japanese multinational corporation and one of the world's largest media conglomerates with revenue of $68.39 billion (as of 2006) based in Minato, Tokyo. Sony is one of the leading manufacturers of electronics, video, communications, video games, and information technology products for the consumer and professional markets. Sony Corporation is an operating-holding company. It is the electronics business unit and the parent company of the Sony Group, which is engaged in business through its 5 operating segments are electronics, games, entertainment (motion pictures and music), financial services and other. These make Sony one of the most comprehensive entertainment companies in the world. Sony's principal business operations include Sony Corporation (Sony Electronics

in

the

U.S.),

Sony

Pictures

Entertainment,

Sony

Computer

Entertainment, Sony BMG Music Entertainment and Sony Financial Holdings. Sony is also among the Worldwide Top 20 Semiconductor Sales Leaders. Its slogan is ³ Sony.Like.No.Other.´

2.2 HISTORY AND VISION

The name 'Sony' was created by combining two words. One was the Latin word, 'sonus,' which is the root word for 'sound' and 'sonic. 'sonic.' The other was 'sunny,' meaning little son. The name symbolizes Sony's spirit and motivation to stay committed to its customers as well as to enhance its reputation in taking its innovations innovations into the t he future of digital technology. Sony has helped developed discerning Malaysians who have come to expect quality, integrity and reliability in audio/visual equipment. Sony's cutting-edge technology brings sights and sounds, expectations and experiences into the home as















Founded by M

ita in 1958, t e Sony Corporation has come u Ibuka and Ak io Mor it

a long way since its f irst trans istor radios. Being innovative thinkers, the founders reali ed a need for a g lobal brand with mass appea l. Hence, as the company grew, it was simply logical to establish produc tion facilities in their respective regions. Since its incep tion, very few have been ab le to match Sony's track record for

invention and innovation. These include the f irst Tr initron colour television (1968), the colour video-cassette (1971), the renowned Wa lkman (1979), the wor ld's f irst C player (1982), the 3.5-inch f loppy disk (1989) and many o thers.

Illustration 2.0: Masaru Ibuka

ita Illustration 2.1: Ak io Mor it

The or igin of Sony goes way back to May 1946. Back then, its or iginal name was Tokyo Tsush in Kogyo K.K. (Tokyo Te lecommunications Engineer ing

Corporation). The founders, Masaru Ibuka and Ak io Mor it ita, want ed a name that can be easily remembered by the wor ld. This was essen tial to achieve success in the global market.

Their vision was for Sony to become an endear ing household name across the

ita came up with the term 'global locali ation' in 1988. globe. With this in mind, Mor it He sa id, "In "In thi this day and age, many companies ies are pursuing glob lobaliza izations, but ins instead tead,, we shou should ld move move ahea ahead d with ith a poli policy cy of globa loball loca locali liza zati tion on,, mean meanin ing g tha that we do

d ul be

in

d

mb

of th lo l

it "















L

2.3

AND LE AL STAT S

SONY CORPORAT CORPORAT ON

Sony's assets are neither its bu ildings, nor its land. Sony's grea test asset is the

image of the four letters: S-O-N-Y. Just as in the past, for Sony to succeed in t he future, it must raise its brand image and crea te innovative products. Innova tive ideas are the mos t impor tant aspect of creating Sony produc ts. Technology suppor ts those

ideas af terwards, but the ideas must come f irst. To create produc ts that alter the industry, we mus t have the abilit y to foresee future trends and the unlimited imagination to dream up new products. Most impor tant of all, we must not onl y think of today, instead we must think three to f ive years from now. We mus t be very perceptive to what our customers want. We want our customers to say," say, "I am glad I purchased a Sony product," so we must create products that pull at their heartstrings.















Type of C of Company Location

Employee Investment

Products Products Manufactur anufactured

Multinational Company

Lot 5, JalanKemajuan, Bangi Industrial Estate, 43650 Bandar BaruBangi, Selangor. RM 972 million (USD 256 million) Color Television LCD Television Projection Television Tuner Deflection Yoke Fly Back Transformer Digital Video Decoder (DVD)

Table 2.0: Company Specification In Malaysia, there are four branches of Sony factory, which is Sony Electronics (M) SdnBhd, Sony Technology Malaysia SdnBhd, Sony Logistics (M) SdnBhd and Sony EMCS (Malaysia) Sdn Bhd. Sony Bangi is one of the factory th

which produced Sony¶s branded Television. It was built in 7 October 1987, the first st

operation and production of this factory begin from 1 April 1988. In earlier this factory is known as SONY TV/Video (M) Sdn. Bhd. because of its only produces TV and Video. However when the SONY Video building was completely launched, the name was changed to SONY TV Industries. Year after year revolution this industries changed to SONY EMCS where divided to KL T ech and Penang Tech. Sony TV not only producing items for local market, in fact almost 90% of SMT (TV) production is to export for foreign markets while the excess for domestic market. This factory introduces the TV from smallest size 14 inches to the largest 61 inches. WEGA is the most popular model nowadays which used flat screen. Besides that, COMBO TV is also produced where this model is the combination of TV and

















2.4 MAIN PRODUCT 1951-1955 The D w 

¡

f Technol Technol og og ical cal Revo Revol l tion tion

¢



£

In 1955, Sony developed the world's first transistor radio. Small and extremely functional, the transistors heralded a new technological technological era with its potential. 1956-1960 The W or or l l i O r M r M arket arket ¤

¥

¦

In 1958, the company officially changed its name to Sony Corporation and this marked a new beginning for the company. As global markets began to grow, products stamped with the Sony trademark were widely gaining acceptance and popularity. During this period, revolutionary technologies and the world's first transistor televisions were developed, paving the way to an electronic revolution and the video tape recorder. 1961-1965 S ony, ony, t he he G inea Pi g g §

During this period, Sony was often referred to as a corporate guinea pig, an experimental animal likely to be gobbled by the big companies that follow behind. Despite this risk, Sony continued to develop new products using transistor technology and led the way to capture ca pture the attention of the world. 1966-1970 Just Ano Anot t her C her C ompany? ompany?

Sony entered a difficult period. Competitors from around the world were nipping at Sony's heels. Sony had just spent a huge amount of time and money developing the colour television, the video tape recorder, and the SOBAX calculator. Despite the economic downturn in Europe and many daunting challenges, Sony finally created a

















1981-1985 Bir t t h o f t he he W al kman kman Generati eneration on

Entering the 80s, Sony forcefully promoted the development of the CD and 8mm video. The introduction of Walkman personal stereos created a huge sensation in the 80s - taking music outdoors anywhere, anytime. It immediately became a lifestyle of young people around the world. Pioneer s in t he he AV nd us ry 1986-1990 Pioneer ust ry ©

Sony was gaining momentum and self-sufficiency, resulting in new product development across all AV fields. Establishing itself in worldwide markets, Sony was fact becoming one of the world's leaders in AV products. 1991-1996 Tow Toward s M ultimed ltimed ia and E and E nt er er t t ainment nment

The digital wave was gathering momentum, making inroads in many areas of life around the world. Sony's operations already encompassed hardware and software, covering audio, video, communications and computers. Sony had already strengthened its position for the 21st century but was now faced with a new challenge - the digital age and making a fresh start towards realizing the dream dr eam of the digital age.

2.5 SONY KL TEC

SONY TECHNOLOGY MALAYSIA (STM) OPENING DATE APRIL 1988

(STM) KL TEC MERGE WITH (STM) PENANG TEC

















Illustration 2.3: KL Tec a t Bandar Baru Bangi

2.6

SOE SO E

y

High

E POR T Quali Quali

buted in R ight Products are produced and d istr i bu ight Quanti Quantiti s to the

R ight ight Locati ocations at the R ight ight Ti

!

















SOEM star ted product design of persona l audio products, such as wa lkman and

y

C

walkman in 1990. And then TV in 1992, and Home Aud io and Video

produc ts in 1994.Lastly from 2006, SOE M star ted LC LC

y

TV design.

TV, DVD player, Home Theater and R ece eceiver are currently 100% des igned

by SOEM. Other categor ies also are des igned by us.

Sony EMCS (Mal (Malaysi aysia)

y

We star ted produc t design of persona l audio produc ts, such as wa lkman and CD

walkman in 1990. And then TV in 1992, and Home Aud io and Video products in 1994. Lastly from 2006, we s tar ted LCD TV design.

Sony EMCS (Mal (Malaysi aysia)

2.6.1 y

Customer Servi Service Acti Activities

SOEM provide excellent Technical Suppor t for a ll our Service Centers in Pan Asia so that they can prov ide fast response for our cus tomer claims. In addition

that SOEm are doing technical information service.

2.7

ETHICAL CAL AND CULT CULTUR UR E OF WORK

To build in good qua lity into SONY products, they promote People

















2.8 COMPANY ORGANIZATION CHART

Video Sector

Video Design

Key Component TV Sector TV Engineering R&D 1 VP Sector

R&D 2 R&D 3 Quality Assurance MCM Asia

KL Manufacturing Centre

Manufacturing Common TV Production DVD Production

Managing Director

Auto Mount Centre

Quality Assurance/ Customer Service Centre

KL Auto Mount

Quality Reliability -KL -KL

Customer Customer Service Service-KL



















2.9

1

2

TELE

ISION

QUAL QUALITY R EASSURANCE ASSURANC E (T

QR) ORGANIZATION CHAR T



















CHAPTER 3 REPORT ON JOB/TASK/ASSIGNMENT/PROJECT

3.1 DEPARTMENT OBJECTIVE

The main purpose and activities of this department is more to testing and measurement for each new model TV. Each new model TV must pass all kind of testing under TVQR before it can be ship to buyer country.There are four small groups under TVQR which is Product Safety (PS), Quality Control (QC), Reliability & Engineering (RE), and lastly Quality Promotion (QP)

3.2 PRODUCT SAFETY

Product safety is one of four groups in TVQR. Purpose of this group is to ensure the safety of the entire new model TV before it can be sell to customers.There are five types of testing that will be done by PS group like leakage current, RIPR, power consumption, consumption, fool proof, and smell s mell test & outgas.



















Leakage current jig Scope meter

Power amplif ier

EUT Illustration 3.0: Step Using Equi pmen pment

3.3.2

WHY USING SCOPE SCOPE METE ETER R



















3.4 REALIBILITY INCIDENT PREVENTIVE RULE

The objective is to ensure TV Business Group products comply with safety regulation in the RIPR.

3.4.1 y

SCOPE

Applicable to all product related to TV Business Group Products, including products designed all produce at parties other than Sony.

y

Component and sub-assembly use for products must satisfy all the requirements describe in RIPR

3.4.2

STAGES

Start General



















3.4.3

ELECTRICAL PART

PWB (Printed Wiring Board) structure. y

Check the component based on the check sheet.

y

Eyelet & normal solder.

y

Clearance.

y

ID marking.

3.4.4

MECHANICAL PART

Consist of plastic part. y

Rear Cover, Neck, Stand Base.

Check External part of TV. y

Dust, scratch, finger print, paint peel.

y

Gap.

Ensuring the PN same as check sheet





















3.5

POWE POWER CONSUMPT CONSUMPTION

The ob jective is to ensure Sony L CD TV energy ra ting is according to the value declared to the country's government.

3.5.1

RULE RULE

1. New model introduced:

3 units per model before Shi pp pping Conf irmation

Meeting. 2. Current model: 1 unit per model per 3 months. hs.



















3.6 FOOL PROOF

The objective is to verify the label on the set with the reference. . 3.6.1

PROCEDURE

Take picture of the following items: y

Combi Label

y

Carton Logo

y

Carton Dimension



















3.7 SMELL TEST & OUTGAS

Preliminary round y

To select members who are able a ble to identify smell test sa mple. mple.

y

Each member will be given 5 samples per rounds.

y

Identify which sample number has SMELL.

y

Circle the sample number on the test sheet.

Final round y

To identify the variance between new tester and current tester a nd calibrate



















3.9

SMELL SMELL TE TES ST & OUT OUTGAS EQUIPME PMENT LIST

BLOW BL OWE ER



















VACUUM

BOX

ELAST ELAS TIC RUBBE RUBBER R





















RUBBEE RUBBEER R COVER



















3.10

y

SMELL SMELL TE TES ST & OUT OUTGAS TE TES STING PROCE PROCEDUR E

Check TV set model name, destination, produc t no, and ser ial no. make sure it same with produc tion schedule.



















y

By us ing both hands, lif t TV carefully from the car ton to prevent defect from occurr ing.



















Put the TV into smell chamber.



















Close the chamber tightly to prevent air from coming out. Af ter the chamber being close, aging the TV for 2 hours.













































































































































































































































Example Practical Report

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