CHAPTER 1 INTRODUCTION

1.1 OVERVIEW Industrial Training (INTRA) is one of the requirements for all KolejKemahiranTinggi MARA &InstitutKemahiran MARA students of

Diploma/Sijil Programmers. The industrial training supplements the students 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.

1.3 INTRA DETAILS COMPANY NAME COMPANY ADDRES SONY EMCS (M) SDN BHD Lot 5, JalanKemajuan, Bangi Industrial Estate, 43650 Bandar Baru Bangi, Selangor Darul Ehsan. 03 - 8925 7587 03 - 59252649 Television Quality Reassurance (TV QR) Mrs. MazlindaBinti Abdul Majid Senior Engineer

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

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 Smell Test and Outgas testing. Other than that, the student need to borrow and return TV set from logistic to do testing and troubleshooting the problem, inspection dissemble,assemble, 5S+2S, and kaizen in the TVQR department.
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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 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.' 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 into the 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 well as the office. In line with Malaysia's VISION 2020, Sonys future will focus on the dynamic digital era with even sharper cutting-edge technology. The future is filled with exciting promises for continuous and rapid growth.
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Founded by M

u Ibuka and Akio Morita in 1958, t e Sony Corporation has come

a long way since its first transistor radios. Being innov ative thinkers, the founders reali ed a need for a global brand with mass appeal. Hence, as the company grew, it was simply logical to establish production facilities in their respective regions. Since its inception, very few have been able to match Sony's track record for invention and innovation. These include the first Trinitron colour television (1968), the colour video-cassette (1971), the renowned Walkman (1979), the world's first C player (1982), the 3.5-inch floppy disk (1989) and many others.

Illustration 2.0: Masaru Ibuka

Illustration 2.1: Akio Morita

The origin of Sony goes way back to May 1946. Back then, its original name was Tokyo Tsushin Kogyo K.K. (Tokyo Telecommunications Engineering Corporation). The founders, Masaru Ibuka and Akio Morita, wanted a name that can be easily remembered by the world. This was essential to achieve success in the global market.

Their vision was for Sony to become an endearing household name across the globe. With this in mind, Morita came up with the term 'global locali ation' in 1988. He said, "In this day and age, many companies are pursuing globalizations, but instead, we should move ahead with a policy of global localization, meaning that we set down roots and truly become an integrated member of the local community." Sony's mission is to establish an 'ideal' factory that puts emphasis on the spirit of freedom and open-mindedness and also a place where designers and engineers can work out their creative and technological skills to the highest potential.
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AND LE AL STAT S

2.3 SONY CORPORAT ON Sony's assets are neither its buildings, nor its land. Sony's greatest asset is the image of the four letters: S-O-N-Y. Just as in the past, for Sony to succeed in the future, it must raise its brand image and create innovative products. Innovative ideas are the most important aspect of creating Sony products. Technology supports those ideas afterwards, but the ideas must come first. To create products that alter the industry, we must have the ability to foresee future trends and the unlimited imagination to dream up new products. Most important of all, we must not only think of today, instead we must think three to five years from now. We must be very perceptive to what our customers want. We want our customers to say, "I am glad I purchased a Sony product," so we must create products that pull at their heartstrings.

Illustration 2.2: Sony Group Companiesin Malaysia

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Type of Company Location

Employee Investment

Products Manufactured

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 Sonys 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 Tech 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 Video. The major target markets are Japan, Australia and West Asia.

2.4 MAIN PRODUCT 1951-1955The D w f Technological Revol tion

In 1955, Sony developed the world's first transistor radio. Small and extremely functional, the transistors heralded a new technological era with its potential. 1956-1960The Worl i O r Market 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. 1961-1965Sony, the G inea Pig 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 the attention of the world. 1966-1970Just Another Company? 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 new colour television, dubbed the Trinitron. 1971-1975Manufacturing Closer To The Market As big corporations around the world began relocating manufacturing facilities to places like Taiwan and Southeast Asia, Sony promptly began setting up a series of overseas manufacturing facilities closer to the consumer market. This was a significant first step towards truly becoming a world enterprise.

1976-1980The Age of Vi eo After 20 years of accumulated research and development of video technology, Sony developed the Betamax VCR - a product seen to create new lifestyles.
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1981-1985Birth of the Walkman Generation 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. 1986-1990Pioneers in the AV ndustry 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. 1991-1996Towards Multimedia and Entertainment 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 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 1 APRIL 2004

SONY NEW NAME SONY EMCS (M) SDN BHD (SOEM)

MANAGING DIRECTOR (SOEM) 2004 MR. T. KIKUCHI

Illustration 2.3: KL Tec at Bandar BaruBangi

2.6 SOE y

E PORT Products are produced and distributed in Right Quantiti s to the !

High Quali

Right Locations at the Right Ti

Figure 5.0: Country of SOE

Export

Sony E CS (Malaysia)

SOEM started product design of personal audio products, such as walkman and C walkman in 1990. And then TV in 1992, and Home Audio and Video products in 1994.Lastly from 2006, SOEM started LC TV design.

LC TV, DVD player, Home Theater and Receiver are currently 100% designed by SOEM. Other categories also are designed by us.

Sony EMCS (Malaysia)

We started product design of personal audio products, such as walkman and CD

walkman in 1990. And then TV in 1992, and Home Audio and Video products in 1994. Lastly from 2006, we started LCD TV design.

Sony EMCS (Malaysia)

2.6.1 Customer Service Activities y SOEM provide excellent Technical Support for all our Service Centers in Pan Asia so that they can provide fast response for our customer claims. In addition that SOEm are doing technical information service.

2.7 ETHICAL AND CULTURE OF WORK To build in good quality into SONY products, they promote People Innovation Hitozukuri. They are making people with high discipline and Habitual Behavior. o First one is meeting in line. o Second is confirmation of job. o Management also gives high motivation to people with morning greeting. o Finally they are confirming the quality at spot.

Spirit Burning (Quality eople, Quality roducts) It is necessary to have a passion for making good quality in products so that we are doing spirit burning and exercise every day.
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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

KL Auto Mount

Quality Assurance/ Customer Service Centre

Quality Reliability -KL

Customer ServiceKL -

Procurement Centre

Procurement Accounting Finance &

Business Strategy Centre

Corporate Planning Production Control KL Tech Information Technology

Human Resources Human Resource & General Affairs Centre General Administration Shared Services

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Sony EMCS (M) KL Tech Organization Chart

2.9 TELE ISION QUALITY REASSURANCE (T QR) ORGANIZATION CHART

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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, fool proof, and smell test & outgas.

3.3 LEAKAGE CURRENT The objective is to protect electric shock when customers touch any terminal at LCD set. To check SOEM LCD TV complies with the RIPR requirement.

3.3.1 PROCEDURE 1. Setup The Equipment (Scope meter, leakage current jig) 2. Change the setting (frequency & voltage) at the power amplifier 3. Measure current from different terminal ( RF, Video 1, Video 2, and DVD) 4. Repeat the process using different setting on power amplifier 5. Record & calculate the current leakage manually in the check sheet. 6. Leakage Current value which is over than 10% than design data should be highlighted to designer. 7.
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Leakage current jig Scope meter

Power amplifier

EUT Illustration 3.0: Step Using Equipment

3.3.2 WHY USING SCOPE METER y y y y Able to give consistent reading from power amplifier. Value will be shown by a graph at the correct frequency. To get accurate and parallel reading compared with design. The reading will not influence any noise NF supply.

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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 SCOPE
y

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

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

3.4.2 STAGES Start General Inspection Mechanical Part Checking Electrical Part Checking Leakage Current General Inspection

End

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3.4.3 ELECTRICAL PART PWB (Printed Wiring Board) structure.

y y y y

Check the component based on the check sheet. Eyelet & normal solder. Clearance. ID marking.

3.4.4 MECHANICAL PART Consist of plastic part.

y

Rear Cover, Neck, Stand Base.

Check External part of TV.

y y

Dust, scratch, finger print, paint peel. Gap.

Ensuring the PN same as check sheet

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3.5 POWER CONSUMPTION The objective is to ensure Sony LCD TV energy rating is according to the value declared to the country's government.

3.5.1 RULE 1. New model introduced: 3 units per model before Shipping Confirmation Meeting. 2. Current model: 1 unit per model per 3 months.

Malaysia

Australia & New Zealand Illustration 3.1: Energy Rating Label

Japan

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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 y y y y y y y y

Combi Label Carton Logo Carton Dimension Pop Sticker Caution Label Warranty Battery AC Cord E-Pop

Transfer the entire picture to the computer. Compare with the reference.

Illustration 3.2: Label Need to Take Picture

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3.7 SMELL TEST & OUTGAS Preliminary round

y y y y

To select members who are able to identify smell test sample. Each member will be given 5 samples per rounds. Identify which sample number has SMELL. Circle the sample number on the test sheet.

Final round
y

To identify the variance between new tester and current tester and calibrate new tester judgment

Each member will be given an air sample collected from the smell test chamber.

Evaluate the smell of the air sample according to the evaluation sheet

3.8 SMELL TEST & OUTGAS PURPOSE Smell test objective is to measure the strength of smell coming from TV within limit in order not to make user to fells uncomfortable. Outgas objective is to ensure customers health is not adverse by monitoring the outgas LCD TV emit has the target chemical within limits set.

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3.9 SMELL TEST & OUTGAS EQUIPMENT LIST

BLOWER

DUMMY SCREW

SCREW DRIVER

SMELL CHAMBER

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VACUUM BOX

ELASTIC RUBBER TUBE

SUCTION PUMP

ODOR BAG

21

RUBBEER COVER

SORBENT SILICA & COCONUT

MINI PUMP

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3.10 SMELL TEST & OUTGAS TESTING PROCEDURE Check TV set model name, destination, product no, and serial no. make sure it same with production schedule.

DESTINATION

MODEL NAME

PRODUCT NO PP GREENLA BEL

SERIAL NO

Use blower to move the tape from carton. The reason why use blower is to ensure the carton not damaged during the tape removal process.

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By using both hands, lift TV carefully from the carton to prevent defect from occurring.

Lift Using Both Hands

Assemble the stand base with TV by using dummy screw and screw driver. This to ensure the TV can stand alone during testing.

Tag the TV and carton with tagging number for identification. This tagging usage is to easier the tester to find the carton after finish testing.

SAME TAGGING NUMBER, FOR EASY IDENTIFICATION

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Put the TV into smell chamber.

Illustration 3.3: TV in smell chamber

Switch On the TV and setting TV to find signal. Make sure signal TV is in all white condition.

Illustration 3.4: TV in all white signals

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

Illustration 3.5: Chamber tightly closed

Illustration 3.6: TV Aging process in chamber

After two hour, take the smell test sample using Odor bag, follow by take outgas sample using sorbent silica and coconut.

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3.11 HOW TO SETTING TV

Select language.

Select area

Select type of use

27

Select position

Start auto tuning

Tuning in progress

28

Tuning finished, it shown number of program found

Set day and time

Setup complete

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3.12 TAKEN SMELL TEST SAMPLE y Use odor bag to take the sample

Put odor bag inside the Vacuum Box

Adjust the vacuum box button to on position like below

30

Make sure the tube is connected from chamber to vacuum box, from vacuum box to suction pump

Switch on the pump, fill the Odor bag with smell sample until half full

When finished, close the Odor bag with rubber cover

31

Ent er the details of such a model, destination, serial no, and date on th e paper provided. Attached t he paper on the Odor bag.

Fill at least four Odor bag with smell test sample. Give the sample to qualift TVQR member for evaluation.

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3.1.3 TAKEN OUTGAS SAMPLE

Using two types of sorbent which is silica and coconut

Take the sorbent and break both end of sorbent using cutter

Inside end of sorbent with cotton into the chamber tube, and the other end of sorbent to mini pump tube.

33

Setting the mini pump according to sorbent specification

Pump Setting

34

Take the sample using mini pump

Each sample had to be taken about hour

y y

When finished, close the sorbent using masker tape Keep sorbent containing outgas sample into the fridge.

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3.14 TYPE OF NEW MODEL There a two types of new model for SONY TV production. The first new model is Pre Production (PP) stages, and the second one is Mass Production (MP) stages. The different of both new models can be seen at illustration below.

GREEN LABEL

Illustration 3.7: PP Stages Label

BLUE LABEL

Illustration 3.8: MP Stages Label

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There are also a model know as current model.

NO LABEL

Illustration 3.9: Current Model Label

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3.15 KAIZEN Kaizen mean improvement or change for better. Kaizen can be practice to improve process in manufacturing, engineering, supporting business, and management. Kaizen had been practice at all SONY factory for a long time.

3.15.1 KAIZEN AT SONY TVQR Kaizen had been practice many years at TVQR. It had become part of tradition at TVQR. There are two types of kaizen that been practice at TVQR which is; physical kaizen and internal kaizen. Physical kaizen is more to thing we can see, touch, and use. For example angle jig. On the other hand, internal kaizen is more to improve management system.

Tuesday had officially selected as a kaizen day at TVQR based on Zero Defect Day (ZDD) are also on the same day.

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CHAPTER 4

CONCLUSION

Industrial Training gives an early exposure of the working environment, practical aspect of what had been learned and application of those theories that had acquired so far. It also develops the students working abilities, competence, and interpersonal skills. In addition, it gives exposure to student and some idea of the future seeking jobs.

Industrial training also exposes the student to rules, regulations, and safety practices in an industrial environment. Besides, it develops the students sense of team spirit in accomplishing a common goal. Student can have high confidence level and experiences to face the challenging and demanding world.

In a conclusion, the training was very interesting for me since I had gained a lot of knowledge and experience. I had learned how to do testing and troubleshooting the problem, dissemble, cleaning, inspection, repair, assemble and testing in the TVQR department. Although I had faced some difficulties during the training, I am still glad to have a new experience in my life. Again, it is my great pleasure to acknowledge and thank to all that have contributed to my industrial training report.

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RECOMMENDATION

There are some suggestions that I would like to propose in order to make this industrial training become more motivating and practical.

I would like to suggest to the KKTM to give more hands on skills during the lab session so the student will have high level of confidence to perform any task before they go for industrial training. The proper guidance on how to do the presentation and report should also be given.

In addition, it is better to have the proper manual prepared by the company to guide the student during their practical training. They also can provide a project that can be accomplished by the student so the student becomes clear on what task they are going to carry out.

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REFERENCES

y y y y y y y y y y y

http://www.sony.com.my/section/corporate http://www.sony.com.my/article/234686/section/sonysstory http://www.sony.com.my/article/234687/section/productmilestones http://www.sony.com.my/article/239931/section/overview http://www.sony.com.my/article/239946/section/sonycompanyoutline http://en.wikipedia.org/wiki/Sony http://en.wikipedia.org/wiki/Luminance http://en.wikipedia.org/wiki/LCD http://en.wikipedia.org/wiki/LED_TV http://en.wikipedia.org/wiki/CCFL Industrial Training Student Handbook & Logbook, KolejKemahiranTinggi Mara

y y y

QR JOB FUNCTION TRAINING SYLLABUS APPENDIX 1: BZ212 MECHANICAL FEATURES THE GENERAL-DAVID SARNOFF AND THE RISE OF THE

COMMUCATIONS INDUSTRY
y y

PIONEERING IN TELEVISION RCA,RobertSobel, Stein & Day 1986,282pp.

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CHAPTER 5

APPENDIX

Illustration 5.1: TVQR North Wing (Product Safety & QC) Layout

42

APPENDIX 2

Illustration 5.2: Proposed Area for General Expenses

43

APPENDIX 3

Illustration 5.3: Set Information Form

44

APPENDIX 4

Illustration 5.4: Jon Item Form

45