FUJITSU COMPONENT (MALAYSIA) SDN BHD

NO. 1, LORONG SATU, KAWASAN PERINDUSTRIAN PARIT

RAJA, 86400 PARIT RAJA, BATU PAHAT, JOHOR

CONTROL PANEL SWITCHES

MUHAMMAD SYAFIQ BIN AZHAR
920601-01-5833
A11KE0237
3 SKEM

Faculty of Electrical Engineering

Universiti Teknologi Malaysia

16 June 2014 to 5 September 2014

1

ACKNOWLEDGEMENT

First of all, I would like to express my thanks and greatest gratitude of Merciful God, for
giving me the strength, the will, the chance, the time, the spirit, the ideas and its blessing to me to
have this successfully Industrial training in Fujitsu Component (Malaysia) Sdn. Bhd for 13 weeks.
Next, I take this opportunity to express my profound gratitude and deep regards to my
guide Dr. Yusri Bin Yunus for his exemplary guidance, monitoring and constant encouragement
throughout the course of this thesis. The blessing, help and guidance given by him time to time
shall carry me a long way in the journey of life on which I am about to embark.
I also take this opportunity to express a deep sense of gratitude to En. Amat Sawal Bin
Surif, Senior Executive of Equipment Engineering Section for his valuable information and
guidance, which helped me in completing this task through various stages.
I am obliged to staff members of Fujitsu Component (Malaysia) SDN BHD, for the
valuable information provided by them in their respective fields. I am grateful for their cooperation
during the period of my assignment.
Lastly, I thank almighty, my parents and friends for their constant encouragement without
them, this assignment would not be possible.

CONTENTS

ACKNOWLEDGEMENT .......................................................................................................................... 2
LIST OF FIGURES .................................................................................................................................... 4
LIST OF TABLES ...................................................................................................................................... 4
CHAPTER 1 : COMPANY BACKGROUND AND ORGANIZATION STRUCTURE ..................... 5
1.1

Introduction of Fujitsu Component (Malaysia) ....................................................................... 5

1.2

Company Profile ......................................................................................................................... 6

1.3

Organization Structure of Equipment Engineering Section ................................................... 7

1.4

Location Map of Fujitsu Component (Malaysia) ..................................................................... 9

1.5

ISO Certification ....................................................................................................................... 10

1.6

Products of Fujitsu Component (Malaysia) ........................................................................... 11

1.7

Philosophy, Vision and Mission ............................................................................................... 12

1.8

Quality Policy ............................................................................................................................ 13

1.8.1

Environment Policy........................................................................................................... 14

1.8.2

Safety and Health Policy................................................................................................... 15

1.9

6S ................................................................................................................................................ 16

CHAPTER 2 : TASK DURING INDUSTRIAL TRAINING ............................................................... 18

2.1

Scope of Training ...................................................................................................................... 18

2.2

Process of Designing and Assembling Machines .................................................................... 19

2.3

Task Given ................................................................................................................................. 20

CHAPTER 3 : MAIN PROJECT (CONTROL PANEL SWITCHES) ............................................... 25

CHAPTER 4 : CONCLUSION................................................................................................................ 28
CHAPTER 5 : PROBLEM AND SUGGESTIONS ............................................................................... 29
REFERENCES .......................................................................................................................................... 30

LIST OF FIGURES
Figure 1: Logo of Fujitsu Component (Malaysia) SDN. BHD. .................................................................... 5
Figure 2: Location Map of Fujitsu Component (Malaysia) .......................................................................... 9
Figure 3: Area of Fujitsu Component (Malaysia) Figure 4: Area of Fujitsu Component (Malaysia) ....... 9
Figure 5: ISO 14001: 2004 Figure 6: ISO 9001: 2008............................................................................ 10
Figure 7: TS 16949: 2009 Figure 8: Sony Green Partner ...................................................................... 10
Figure 9: Relay Product .............................................................................................................................. 11
Figure 10: Keyboard Product ...................................................................................................................... 11
Figure 11: Tools and Die
Figure 12: Stamping.................................................................................... 12
Figure 13: Relay Mould
Figure 14: Keyboard Mould ......................................................................... 12
Figure 15: ZN030-0123-W0300 (Drawing Paper) Figure 16: ZN030-0123-W300 (Finished) .............. 20
Figure 17: Tower Light ............................................................................................................................... 21
Figure 18: ZN030-0112-U100 (Drawing Paper)......................................................................................... 22
Figure 19: Drilling Wiring Box .................................................................................................................. 22
Figure 20: Wiring Box (Before)
Figure 21: Wiring Box (After) .......................................................... 23
Figure 22: Wiring Box (Complete) ............................................................................................................. 23
Figure 23: Assembling The Machines Frame ............................................................................................ 24
Figure 24: Machine's Condition on Last Day ............................................................................................. 24
Figure 25: Status 1
Figure 26: Status 2 ............................................................................................... 25
Figure 27: Status 3 (Finished) ..................................................................................................................... 25
Figure 28: Status 1
Figure 29: Status 2 ............................................................................................... 26
Figure 30: Status 3 (Finished) ..................................................................................................................... 26
Figure 31: Status 1
Figure 32: Status 2 ................................................................................................ 27
Figure 33: Status 3
Figure 34: Status 4 ............................................................................................... 27
Figure 35: Status 5 ...................................................................................................................................... 27

LIST OF TABLES
Table 1: Process of Designing and Assembling Machines..19

CHAPTER 1 : COMPANY BACKGROUND AND

ORGANIZATION STRUCTURE
1.1

Introduction of Fujitsu Component (Malaysia)

Figure 1: Logo of Fujitsu Component (Malaysia) SDN. BHD.

Fujitsu Component (Malaysia) Sdn Bhd (FCM) is a Malaysian based subsidiary of Fujitsu
Component Limited, Japan.
Established in October 1980, FCM began commercial production of electromagnetic relay
coils thereafter assembled by Fujitsu (Singapore) Pte. Ltd., then the parent company of FCM. Due
to Fujitsu's globalisation policy and the recognition of FCM as a major overseas electromechanical
devices manufacturing base, the ownership of FCM was transferred to Fujitsu Limited, Japan in
June 1986. In July 1995, Fujitsu Takamisawa Component Limited was formed to strengthen the
collaboration of technical expertise between Fujitsu Limited Japan and Takamisawa Electric
Company Limited. FCM thus became a subsidiary of this newly formed company. Fujitsu
Takamisawa Component Limited had since become Fujitsu Component Limited and Nagano
Fujitsu Component Limited, with FCM being a subsidiary of Nagano Fujitsu Component Limited
under Fujitsu Component Limited. Now FCM is a subsidiary of Fujitsu Component Limited,
Japan.

Today, FCM's product focuses on two key areas of electromechanical components Relays
and Keyboards, and their parts thereof. For support purposes FCM also manufacture dies and
assembly machines for the electronic products. FCM products are sold through the worldwide
network of Fujitsu Component sales offices, whilst technical and administrative supports are
provided by Shinano Fujitsu Limited and Miyazaki Fujitsu Components Limited.
In 1987, FCM started producing keyboard and connectors too, and from 1987 to 1989, the
moulding, stamping and planting process were transferred to FCM to support the assembly
process. With over 20 years of experience and expertise in the electronic components business and
advancing into the new millennium, the companys hallmark has always been an insistence on an
unswerving commitment to customer satisfaction.

1.2

Company Profile

Company Name

Fujitsu Component (Malaysia) Sdn.Bhd

Address

No.1 Lorong Satu, Kawasan Perindustrian Parit Raja, 86400 Parit

Raja, Batu Pahat, Johor. Malaysia.

Telephone

07-4542111

Facsimile

074541771

Industry

Electric and Electronic component

Established

9th October 1980

Paid Capital

RM 183, 800, 000.00

Authorized Capital

RM 200, 000, 000.00

Operation

Since 1980 (34 years operation in Malaysia)

Ownership

100% owned by Fujitsu Component Limited

Product

Notebook Keyboard and Relay

Status

LMW- Licensed Manufacturing Warehouse

Man Power

1,482 work forces (June 2014)

Certification

ISO 9001: 2008, ISO 14000: 2004, Sony Green Partner,

TS 1649:2009

1.3

Organization Structure of Equipment Engineering Section

1.4

Location Map of Fujitsu Component (Malaysia)

Figure 2: Location Map of Fujitsu Component (Malaysia)

Figure 3: Area of Fujitsu Component (Malaysia)

Figure 4: Area of Fujitsu Component (Malaysia)

1.5

ISO Certification

All FCM products are manufactured using highly automated process and under the most stringet
of quality control procedures. The information listed below shows the date of the first certification
for an ISO standard. Maintenance audits are conducted anually to ensure the continued adherence
to the specification.

Figure 5: ISO 14001: 2004

Figure 7: TS 16949: 2009

Figure 6: ISO 9001: 2008

Figure 8: Sony Green Partner

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1.6

Products of Fujitsu Component (Malaysia)

1. Relay product since 1986

a. Telecommunication and signal relay
b. Automotive relay
c. Power relay

Figure 9: Relay Product

2. Keyboard product since 1987

a. Semi Complete

Figure 10: Keyboard Product

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3. Part of Thereof

Figure 11: Tools and Die

Figure 13: Relay Mould

1.7

Figure 12: Stamping

Figure 14: Keyboard Mould

Philosophy, Vision and Mission

Philosophy

Fujitsu will always strive to provide innovative, superior goods and services to its
customers throughout the world. In doing so, Fujitsu Component will establish
and maintain harmonious relations locally and internationally.

Fujitsu Component seeks to make a positive contribution to world society.

Visions Statement

To be a global leader in Electro-Mechanical component parts manufacturing, fully

pleasing our customers.

12

Mission Statement

Fujitsu specializes in the manufacturing and installation of specific products for

the customers.

Fujitsu Component Group Mission

As the business partner global market, Fujitsu Component Group continuously

provides the high reliable and high quality products, technological proposals
and strong cost competitiveness for the customers and realizes the growth and
profit as well as contribution for the environment and societies.

1.8

Quality Policy

Fujitsu Component (M) Sdn. Bhd. specializes in the manufacturing and installing
of specific products, supplies to worldwide market.

Our policy is:

QUALITY WORK ENHANCES QUALITY PRODUCTS

In order to achieve the above objective, it is our policy to establish and maintain
the efficiency and effectiveness of quality assurance programme.

We plan and develop it in conjunction with all management functions in FCM:

a. We seriously look into the achievement of total quality management.
b. We are committed to provide total quality in all FCMs activities.
c. We are prepared to provide quality products and services that satisfy
beyond customers requirement.
d. We believe that quality improvement is an infinite programme.

We will initiate Continuous Improvement in all process of the production.

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1.8.1 Environment Policy

FCM recognizes that global environmental issues are extremely important,

because human being is one of constituent element of Earth. With that in mind,
FCMs environmental policy statement shall be
We Love Nature!
and the details of this policy is carried out as follows.

We shall promote environmental management system according to ISO 14001

requirements.

We shall be aware of environmental aspects of activities, products and services

and promote prevention of environmental pollution in FCM.

We shall improve continually environmental management system in FCM.

We shall comply with relevant environmental legislation, regulations and other

requirement for environmental aspects of activities, products, and services in
FCM.

We shall continuously make the effort to minimize impact on the environment

through effective management of resources and waste wherever possible.

To achieve FCM environmental policy we shall set environmental objectives and

targets which shall be periodically reviewed and revised to reflect changing
conditions and information.

FCMs environmental policy shall be communicated to all employees and can be

made publicly available.

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1.8.2 Safety and Health Policy

FCM is committed to provide a safe and healthy workplace for all its employees
and visitors.

With the available resources, FCM will comply with all relevant legislation to
ensure the safety, health and welfare of all employees.

FCM will address hazard control, accident prevention and rehabilitation as

priorities.

Safety and health is both an individual and shared responsibility of ALL

employees. FCM places safety and health on a priority equal to production.

Management is responsible to:

o Integrate safety and health into all aspects of the work place.
o Take effective action to provide and maintain a safe and healthy work
environment.
o Disseminate information and promote communication on safety and
health.
o Plan, develop, implement and monitor the safety and health program.

Employees are responsible to:

o Work in a safe and health manner.
o Encourage others to work in safe and healthy manner
o Discourage others from working in an unsafe manner.
o Co-operate with support and promote safety and health in work place.
o Report any unsafe conditions that come to attention at work.

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The Safety and Health Committee will:

o Endeavour to reach consensus through the process of joint consultation.
o Jointly work with responsible for managing safety and health in FCM

1.9

6S

1S: Seiri (Sort)

Keep only essential items and eliminate what is not required, prioritizing things as per
requirements and keeping them in easily-accessible places. Everything else is stored or
discarded.
2S:Seiton (Arrange)
There should be a place for everything and everything should be in its place. The place for each
item should be clearly labeled or democrated. Items should be arranged in a manner that
promotes efficient work flow , with equipment used most often being the most easily accessible.
3S: Seiso (Clean)
Keep the workplace tidy and organized. At the of each shift, clean the work area and be sure
everything is restored to its place. This makes it easy to know what goes where and ensures that
everything is where it belongs.
4S: Seiktetsu (Standard)
Work practices should be consistent and standardized. All work stations for a paricular job
should be identical. All employees doing the same job should be able to work in any station with
the same tools that are in the same location in every station. Everyone should know exactly what
his or her responsibilities are for adhering to the first 3Ss.

16

5S: Shitsuke (Disipline)

Maintain and review standards. Once the previous 4Ss have been established, they become the
new way to operate. Maintain focus on the new way and do not allow a gradual decline back to
the old ways. While thinking about the new way, also be thinking about the new way, also be
thinking about yet better ways. When an issues arises such as a suggested improvement, a new
way of , a new tool or a new output requirement, review the first 4Ss and make change as
apppropriate.
6S: Setsuyaku (Saving)
Reduce electric and water wastage. Complying with the conditions stated in ISO 14001 which
emphasis on saving of electrical energy, water, resin, papers, and hydraulic oil.

Benefit 6S to FCM

Productiviyt increase, reject decrease, output improve

Safety workplace, less industrial accident

Product quality gurantee, no customer refund

Cost decrease (Raw material, insurance, labor)

Reputation lead Customers trust

Delivery on time

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CHAPTER 2 : TASK DURING INDUSTRIAL TRAINING

2.1

Scope of Training

Equipment Engineering Section is a department of designing and assembling new

machines to be used in production line either in relay production or keyboard production.
During my industrial training at Fujitsu Component (Malaysia), I was placed at
Equipment Engineering Section to help the staff at Equipment Engineering Section to
assemble the machines. Equipment Engineering Section is charged by Mr. Okabe Hitoshi
who is the manager of Equipment Engineering Section and his assistant manager is Mr
Yiang Soo Keong. Next, Mr. Amat Sawal bin Surif is my supervisor and his designation
in Equipment Engineering Section is Senior Executive.

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2.2

Process of Designing and Assembling Machines

NO.
OF

PROCESS

STEPS
1.

Design machines using AutoDesk software.

2.

Program ladder diagram coding using CXprogrammer software to use in PLC.

3.

Order all the part of the machines

4.

Check all the part list that are ordered that arrived.

5.

Sort all the part in basket.

6.

Assemble the parts and wiring the machines.

7.

Alignment all part of machines.

8.

Assemble all the parts.

9.

Machines is ready to operate.

10.

Collect all the data of the machines to be analyze.

Table 2: Process of Designing and Assembling Machines

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2.3

Task Given

Assembling ZN030-0123-U100 project, Coil Winding Unloader Stocker.

This machine was conducted by Mr. Amat Sawal bin Surif to assemble. I managed to
help him to finish his project. This project had three unit of machine to assemble. First of
my tasks given were to complete the assembling of the machines frame by using
aluminum profile for three sets. Figure 15 shows the drawing paper that was given to me
to assemble. Then, Figure 16 shows the frame that I had finished assemble. Figure 16
also shows that I had finished assemble the plastic cover of the machine.

Figure 15: ZN030-0123-W0300 (Drawing Paper)

Figure 16: ZN030-0123-W300 (Finished)

20

Moreover, I was also given a task to assemble the tower light to the machines and cut the
tower light to become shorter than the original length. I cut the metal by using two ways,
the first one, I cut it by using G-cutter and it took some time to finish. Then, I used a
grind machine to cut the metal and it was easier and faster than before. Figure 17 shows
that the tower light that had been assembled on the machine.

Figure 17: Tower Light

Assembling ZN030-0112-U100 project, Magazine Loading.

This machine was also conducted by Mr. Amat Sawal bin Surif to assemble and I also

managed to help him to finish his project. This project had two units of machine to be
assembled and Mr. Amat Sawal bin Surif assigned me to assemble all the parts from the
beginning. First of all, I need to check the checklist of all the parts that had been ordered
by Mr. S. K. Yiang. After that, by using computer of Mr. Amat Sawal bin Surif, I
observed the 3D drawing of the machine in AutoDesk software. I also studied the 2D
drawing by using a reference drawing paper of the machine. Then, after studied all the
drawings, I managed to assemble all the metal parts of the machines. Figure 18 shows the
2D drawing paper of the machine, ZN030-0112-U100 project.

21

Figure 18: ZN030-0112-U100 (Drawing Paper)

Next, I had been assigned to drill and chamfer the wiring box of these machines. First of
all, I needed to measure the point where the hole need to be drilled. Then, the point of the
hole was marked by the center punch. After that, the mark was drilled by a driller.
Chamfering was done after drilling to clear the burry of the hole. Lastly, the area of work
was cleaned. Figure 19 shows how the drilling was done.

Figure 19: Drilling Wiring Box

22

Then, I continued wiring the wiring box. Figures 20 and 21 shows the wiring box before
and after the component was placed in the wiring box. Figure 22 shows that the wiring
box was completely done.

Figure 20: Wiring Box (Before)

Figure 21: Wiring Box (After)

Figure 22: Wiring Box (Complete)

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 Assembling ZN030-0124-U100 project, FTR P3 Blowing and Covering Machine.

Mr. Fauzi was the person in charged in assembling these machines. This project had three
units of machines to assemble. Unfortunately, I did not managed to help him to finish his
project completely because my duration time of internship was not enough. As usual, the
frame of the machine was set up. Then, my tasks given were to complete the assembling
of the machines parts. Figure 23 shows that the frame of the machine was assembled.

Figure 23: Assembling The Machines Frame

Then the assembling process was proceed until the machine is done. Figure 24 shows the
machines condition for my last day of internship at Fujitsu Component (Malaysia) SDN
BHD.

Figure 24: Machine's Condition on Last Day

24

CHAPTER 3 : MAIN PROJECT

(CONTROL PANEL SWITCHES)

My main project was assembling, wiring and finishing the control panel switches for all the
project that were assembled during industrial training at Fujitsu Component (Malaysia) SDN
BHD. I managed to finish the control panel switch for ZN030-0123-U100 project, Coil Winding
Unloader Stocker for two units and ZN030-0112-U100 project, Magazine Loading for one unit.
For ZN030-0124-U100 project, FTR P3 Blowing and Covering Machine for one unit, I only
made it halfway.
ZN030-0123-U100 project, Coil Winding Unloader Stocker.

Figure 25: Status 1

Figure 26: Status 2

Figure 27: Status 3 (Finished)

25

 ZN030-0112-U100 project, Magazine Loading.

Figure 28: Status 1

Figure 29: Status 2

Figure 30: Status 3 (Finished)

26

 ZN030-0124-U100 project, FTR P3 Blowing and Covering Machine.

Figure 31: Status 1

Figure 32: Status 2

Figure 33: Status 3

Figure 34: Status 4

Figure 35: Status 5

27

CHAPTER 4 : CONCLUSION

Control panel switches is the most important part of designing machines. There were
many types of control panel switches that need to assemble on machines, every machines come
with different function of it. In conclusion, the control panel switches that I was assembled is
used to control the machines either in manual condition or automatic condition.

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CHAPTER 5 : PROBLEM AND SUGGESTIONS

My industrial training that already last for 12 weeks has successfully opening my views
of what this field is all about. But, what I have through during this period of time, I think that the
time of my industrial training was not enough to get all the knowledge and to feel the true
experience of working in industrial. Thus, to finish and study all the information of control panel
switches, I need more time in industrial training.

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REFERENCES
1) http://www.fujitsu.com/my/about/subsidiaries/fcm/
2) http://en.wikipedia.org/wiki/5S_(methodology)
3) https://translate.google.com.my

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