CHAPTER 1 INTRODUCTION

COMPANY BACKGROUND The history of Clipsal Founded in Australia in 1920, Clipsal has become one of the leaders in electrical accessory products, known for its innovation and quality, in Asia 1920! Alfred "erard developed the product that #ave the company its name, an ad$ustable, one si%e &clips all' metal conduit fittin# (he company spearheaded several manufacturin# breakthrou#hs, includin# the first all)Australian switch in 19*0 +n the 19,0s the company pioneered thermoplastics which led to world firsts includin# the -.C Cord top, vertical combination switched socket and more /urin# the 1900s the company be#an e1portin# to Asia well before it became the practice of Australian companies (he famous 2 3eries accessories proved to be very popular throu#hout the Asian re#ion +n the 40s and 90s the Clipsal brand continued to e1pand on the stren#th of many innovative products, reachin# its market leadin# position that it currently en$oys +n the last decade, the company5s /atacomms division has for#ed ahead as a market leader in the data communications market while the company5s C)6us automation technolo#y has become the main supplier of buildin# and home automation to both commercial and residential markets 7ver the years, Clipsal has #rown and evolved with #reat success (heir marketin# initiatives and consumer campai#ns ensure commitment to valued customers 3ome of the more prominent initiatives include ) Club Clipsal +nternational, /emand (he 6rand, Clipspec and (he 2ssential Checklist I !""#$ %&h ei'er Ele&tri& a&()ire' Clipsal* (his important acquisition fulfilled a vital niche for the 3chneider 2lectric "roup, securin# market leadership of the Australian and Asia -acific electrical accessories residential market and a ma$or stron#hold in the automation and data communication markets*
1

The history of %&h ei'er Ele&tri& %&h ei'er Ele&tri&+s Ti,eli e From 14*8 to today, 3chneider 2lectric has transformed itself into the #lobal specialist in ener#y mana#ement 3tartin# from its roots in the iron and steel industry, heavy machinery, and ship buildin#, it moved into electricity and automation mana#ement After 100 years of history, 3chneider 2lectric has become today the solution provider that will help you make the most of your ener#y /iscover its transformation below 19th century 1-#.! (he 3chneider brothers took over the Creusot foundries (wo years later, they created 3chneider 9 Cie 1-/1! :avin# become an armaments specialist, 3chneider innovated by launchin# itself into the emer#in# electricity market First half of the 20th century 1/1/! +nstallation of 3chneider in "ermany and 2astern 2urope via the 2uropean +ndustrial and Financial ;nion <2+F;= +n the years that followed, 3chneider associated with >estin#house, a ma$or international electrical #roup (he "roup enlar#ed its activity to manufacturin# electrical motors, electrical equipment for power stations and electric locomotives Post 0ar! 3chneider #radually abandoned armaments and turned to construction, iron and steel works and electricity (he company was completely reor#anised in order to diversify and open up to new markets ?ate 20th century 1/-111//2! 3chneider "roup continued to focus on the electrical industry by separatin# from its non)strate#ic activities (his policy was #iven concrete form throu#h strate#ic acquisitions by 3chneider "roup! (elemecanique in 1944, 3quare / in 1991 and @erlin "erin in 1992 1///! /evelopment of +nstallation, 3ystems and Control with the acquisition of ?e1el, 2urope5s number two in electrical distribution +n @ay 1999 the "roup was renamed 3chneider 2lectric, to more clearly emphasise its e1pertise in the electrical field (he "roup en#a#ed in a strate#y of accelerated #rowth and competitiveness 2arly 21st century !"""1!""/! -eriod of or#anic #rowth, positionin# itself in new market se#ments! ;-3 <uninterruptible power supply=, movement control, buildin# automation and security throu#h acquisitions of A-C, Clipsal, (AC, -elco, Aantre1, becomin# the #lobal specialist in ener#y mana#ement
2

!"1"! 3chneider 2lectric stren#thens its lead in the development of the 3mart "rid, with the acquisition of the distribution activities of Areva (9/ !"11! 3chneider 2lectric acquires leadin# software firm (elvent to reinforce its solution capability for the smart #rid and mission)critical infrastructure

Malaysia Operatio s ,ilesto es

Fi#ure 1 1! (ime ?ine

Pro')&t Ma )fa&t)re'

ORGANI3ATIONA4 CHART 1*!*1 Or5a i6atio al Chart of Clipsal 7y %&h ei'er Ele&tri& 8M9 %' * Bh'*

@y self attach to -roduct 2n#ineerin# 3A3+(:ABBAC

REDDY

Fi#ure 1 2! 7r#ani%ation Chart

1*!*! E:pla atio of Clipsal 7y %&h ei'er Ele&tri& 8M9 %' * Bh'* Or5a i6atio Chart (he red line is the path leads to me from my supervisor @y supervisor who is @r ?im Diat 3an the 2n#ineerin# @ana#er for 3chneider 2lectric @alaysia + was directly placed under his supervisation in the -roduct 2n#ineerin# /epartment (he -roduct 2n#ineerin# as you can see there are two senior product en#ineer<+mtia% and 3hafiee= and two product en#ineer<Chin and Anson= and myself as the trainee alon# with /ev Anand the -ro$ect 2n#ineer and Corita as 2n#ineerin# assistant As you can see the "eneral @ana#er for this or#ani%ation is @r Anson Ale1ander, under his 3ervice will have (he @ana#er of all /epartment attached

MI%%ION AND ;I%ION %&h ei'er<s Missio (o support our customers across world by providin# superior products and services of e1ceptional quality and value (o create lon#)term shareholder value by meetin# or e1ceedin# our customers5 e1pectations of quality as we deliver our products and services on time and on bud#et (his will be achieved by creatin# a fully participatory environment supported by necessary resources, while maintainin# the hi#hest ethical standards Helpi 5 people ,a=e the ,ost of their e er5y* :ave you ever dreamed of improvin# your bottom line while consumin# less ener#y and without a power outa#eE >e can help you solve this problem with solutions to make ener#y safe, reliable, efficient, productive and #reen from plant to plu#

%&h ei'er<s ;isio C)sto,er satisfa&tio is our number one priority! our supply chain is market driven and our approach is se#mented by type of customer and by customer requirements >e build stron# &o,petiti>e a'>a ta5es throu#h our industrial operations and #lobal supply chain mana#ement >e raise our i ')strial a ' s)pply &hai worldwide level &o,pete &ies to the best

>e develop a culture of &o ti )o)s i,pro>e,e t with the contribution of every employee, every day >e make all of our decisions based on s)stai a7le 'e>elop,e t ?e see a 0orl' 0here 0e &a &o,,o pla et* a&hie>e ,ore$ 0hile )si 5 less of o)r

>e know that ener#y demand will skyrocket whilst we will have to drastically cut ":" <#reenhouse #as= emissions >e also know that more than F0G of ":" emissions, are caused by industry buildin#s and residential markets (herefore, we provide ener#y efficiency solutions that can brin# up to *0G of ener#y savin#s, now

1*@

OBAECTI;E% AND BUNCTION% OB DEPARTMENT ATTACHED Pro')&t E 5i eeri 5 Tea,

+n my case, + was in product 2n#ineerin# team, the ob$ectives of this department are ! -rocess of desi#nin# and developin# a device, assembly, or system such that it be produced as an item for sale throu#h some production manufacturin# process -roduct en#ineerin# usually entails activity dealin# with issues of cost, producibility, quality, performance, reliability, serviceability and user features (hese product characteristics are #enerally all sou#ht in the attempt to make the resultin# product attractive to its intended market and a successful contributor to the business of the or#ani%ation that intends to offer the product to that market +t includes desi#n, development and transitionin# to manufacturin# of the product (he term encompasses developin# the concept of the product and the desi#n and development of its mechanical, electronics and software components -roduct en#ineerin# is an en#ineerin# discipline that deals with both desi#n and manufacturin# aspects of a product

Area of Respo si7ility -roduct en#ineers define the yield roadmap and drive the fulfillment durin# ramp)up and volume production, +dentify and reali%e measures for yield improvement, test optimi%ation and product costturability methods, /efine qualification plan and perform electrical characteri%ation analysis

10

CHAPTER ! PROAECT

!*1
2.1.1

PROAECT 1C D)ality E ;al)e E 5i eeri 5 8D;E9

Task Description

+ was assi#ned to do pro$ects on the Huality 9 .alue 2n#ineerin# <H.2= (he purpose of this pro$ect is to reduce cost without affectin# the quality of the part or product (here is some is an important consideration for H.2 cost reduction that has to be followed durin# the pro$ects which is! >e must not compromise product quality or performance >e must respect and fulfill all statutory 9 standards requirements Communicate with B9/ before you start any H.2Icost activity plan Follow -2- process for chan#e mana#ement

!*1*! Te&h i()eFMetho'olo5y Use'

11

!*1*#

Tools Use'C Har'0are a ' %oft0are %pe&ifi&atio s

System Application and Product in Data Processing (SAP) 3A- is the JsoftwareJ enterprises Besources -lannin# <2B-= which is an +( and mana#ement tools to help a company perform operational activities more efficiently and effectively 3A- consists of a number of application modules with total capacity of all the transactions required by the company and each application function associated with each other 1 (he purpose of this 3A- is implemented as! ) +ncrease speed <(he 3peed= from the company +mprove the quality of customer service +mprove response to chan#e and the lack of a product or component

2 +mprove consistency <(he consistency= of the company

12

2nsure 3tandard 7peratin# -rocedures <37-s= performed well

+mprove the monitorin# and control functions Beduce the common errors made by humans <human errors=

* +mprove the quality <(he Huality= from the company +mprove the quality of information so as to improve the ability of 3A- to takin# decisions quickly and accurately +mprove the function analysis of the situation

!*1*@

Pro7le,s a ' %ol)tio s Of The Pro7le,s

D;EFPro')&ti>ity

13

Bi5)reC %ho0s the ProGe&t tea, Me,7ers The pro7le,s a ' %ol)tio

Bi5)reC %ho0s the Before a ' after the D;E As you can see in the fi#ure this pro$ect that we did which is Beduce si%e of contact point from , mm diameter to F mm diameter 6y doin# this action we mana#e to save and capture the savin# for our company, from initial 1 0029 @KB to 0 9029 @KB

Bi5)reC %ho0s the Before a ' after the D;E

14

As you can see in the fi#ure this pro$ect that we did which is -/C31*22@ chan#e type 2AB(: (2B@+CA? A33K)D 6y doin# this action we mana#e to save and capture the savin# for our company, from initial cost for per piece 1 F09F @KB to 0 4809 @KB

(he savin# that we mana#e to capture are about 000k 2uro per annual last year due to H.2 cost reduction /etail as below

15

Fi#ure! 3hows the (op 10 H.2 pro$ect and the Cost Beduction

!*1*H

D)ratio F%&he')le*

(he schedules are classified and confidential, are not to be circulated out the company :owever, + am safe to say that the duration for this pro$ect is really depends on the approval by the B9/ team from Australia and China

!*!

PROAECT !C TRIA4 RUN ON THE PRODUCT%

J(rial BunJ is a process that must be undertaken by the -roduct 2n#ineerin# <-2= to test and ensure that the products are in #ood condition 7ften, a trial run carried out when a product e1periencin# problems when processed, receivin# complaints from customers or create new products /epartments involved in the process of Jtrial runJ is -2, HA, -lanner and (rainers 9 ?eaders Assembly -roducts under#o a trial run will be tested by HA whether the product is applicable or not +f the product is e1periencin# the problem when the Jtrial runJ or when tested by HA, the -2 should solve the problem

!*!*1

Tas= Des&riptio

(he tasks that #iven to me are to conduct the (rail run on the products which is havin# problem or for any new products +t means if there are any problem occur durin# the assembly we need to assess what are the issue related to this problem and liaise with other department to solve this issue before it runs for the mass production (he functional test, dimension check and fittin# test will proceed with after the

16

completion of this trial run After that all, we can proceed to release the LB@-5 release for mass production !*!*! Te&h i()eFMetho'olo5y Use'

1 Choose a product <F"= to #o on a trial run ;sin# 3A- transaction code <@/0F= to check whether a component is run in production or not >ith this transaction, the -2 can find products which use the component

Choose products that use these components in lar#e quantities +f the product is not of complete product, use the 3A- transaction code <C31,= to find out the complete product

17

After knowing the product, download the list of components using SA transaction code !"S12#.

2 -lanner plan to carry out a trial run

After #ettin# the date, time and place of conductin# a trial run, HA and (rainers 9 ?eaders Assembly will be invited to $ointly conduct a trial run

18

* "et results on Jtrial runJ After conductin# a trial run, the product will be tested by HA whether the product is e1periencin# the problem or not +f you do not e1perience any problems, the products can be carried out in production

+f the product is e1periencin# the problem, the -2 should solve the problem.

Tools Use'C Har'0are a ' %oft0are %pe&ifi&atio s System Application and Product in Data Processing (SAP) 3A- is the JsoftwareJ enterprises Besources -lannin# <2B-= which is an +( and mana#ement tools to help a company perform operational activities more efficiently and effectively 3A- consists of a number of application modules with total capacity of all the transactions required by the company and each application function associated with each other 1 (he purpose of this 3A- is implemented as! ) +ncrease speed <(he 3peed= from the company +mprove the quality of customer service +mprove response to chan#e and the lack of a product or component

2 +mprove consistency <(he consistency= of the company 2nsure 3tandard 7peratin# -rocedures <37-s= performed well +mprove the monitorin# and control functions Beduce the common errors made by humans <human errors=

19

* +mprove the quality <(he Huality= from the company +mprove the quality of information so as to improve the ability of 3A- to takin# decisions quickly and accurately +mprove the function analysis of the situation

Testi 5 %pe&ifi&atio a ' Tools for Testi 5 <BU33ER< Check the sound +f there is problem of products, bu%%ers will sound

IBa)lty 4IGHTI +f there is any problem in the product, JFaulty li#ht Mwill flash

IPU%H BUTTONI -ush button is a tools for startin# a tester process :ow to use it is simply pressin# the J-ush 6uttonJ is by hand

I%TART KEYI Function is similar to the J-ush 6uttonJ :ow to use it is to turn the key to start the tester

IPIN PROBE TE%TI +t is the e1amination shutter in #ood condition or not :as 2 small pins +f the pin le# problems, chan#e the pin with a new pin

20

Check the pin le# e1tensions usin# multimetres

IEAECTOR PIN CONDITIONI +f the pin surface is not flat or too short to not be in contact with continuity on the product, replaces the pin with a new pin IDete&t PRODUCT %EN%OR F PU%H BUTTONI J-/3J is a device used to move the product in the JrailJ bo1 to run the e1periment without usin# hand pressure forces (ester uses detector sensor products -ush 6utton Jfunction similar to theJ -/3 Jbut does not use the sensor tester (ester is usin# its pressure to move the product +f J-ush 6uttonJ e1periencin# problems due to re#ular use, replace J-ush 6uttonJ to new I4CD %CREENI A display for displayin# each of the problems e1perienced durin# the process of product trials performed I%CRE? CONDITIONI Checkin# the screws from the product +f there are no screws on the product, JFaulty li#ht Mwill flash

I%ABETY CO;ERI Checkin# the JcoverJ to JcoverJ is in #ood condition

IRAI4I Check whether there is a problem in the part or not

21

I4ATCHI Check whether there is a problem in the part or not

IRelaysI Check JrelaysJ functions or not 3creenin# is done by usin# a multimeter

IAIR CY4INDER E T)7i 5I Check the inner cylindrical tube either loose or wind out there

I%O4ENOID ;A4;EI 21amine the JsolenoidJ if there is any problem

IMCBI +s the power supply Check with the multimeter in #ood condition or not

I4IMIT %?ITCHI Connect the pin +f there is a problem of a missin# screw J, checkJ limit switch Jas likely to cut wires solderin# method is a solution to the problem

ITRAN%BOMERI Checkin# the functionality of the variables +f there are any problems, replace with J(ransformersJ new

IHIGH ;O4TAGE 4IGHTI

22

(he tool checked by HA +f the li#ht is on, all trial on the products is in #ood condition

ICY4INDERI /efinition! ) -neumatic Cylinders ;sin# air pressure differences to produce a style and movement Chan#e the air potential ener#y, mechanical ener#y applied to the kinetic ener#y of motion stren#th (he pneumatic system can drive I interestin# I lift somethin# ob$ects or #oods I%O4ENOIDI /efinition! ) (he term physics)wire loop >hen an electric current flow, the ma#netic field will be produced A variety of transducer devices that convert ener#y into linear

23

Figures of Tester

24

$igure% Tester $ront &iew

$igure% Side &iew

$igure% Top &iew

25

26

27

!*!*@

Pro7le,s a ' %ol)tio s Of The Pro7le,s

1. roduct%'ESM15

Huantity! )4 3uccessful! ), Cot successful! )* -roblem! ) -roduct burnt after the trial M:i#h).olta#eM <2D. N80 .= 21pectations!)-ossible causes of the problem of the MbaseM and MplateM or 7ne of them

Analysis! ) Chan#e the MbaseM <not 7D= with the M-lateM <7D= Besult! ) <Cot 7D=

Chan#e the MplateM <not 7D= to the MbaseM <7D= Besults !)< 7D=

(he final decision! ) (he problem is due to the MbaseM Huestion! >hat is the problem in the MbaseME Answer! +mproper solderin# is done

2 -roducts! )1H#-F.010h

-roblem! ) M3hutter $ammedM (he question! ) (here is a problem MFlashin#M in the M3hutterM Analysis! ) Found MFlashin#M in the MshutterM Besults!)successful

28

(. roduct%'1661L-XX-YY ro)lem%'*ot ha+ing a shutter in the product. "ause%'error of the operator. Results% ,perators imposed disciplinar- action form.

/=-roduct!)The so&=et -roblem!)All components installed in the product enou#h, but durin# the trial the MtesterM failed 21pectations!)(erminal ? I C I 2 cannot be in effect in the MtesterM Cause!)(he problem of the MtesterM Res)lts 819!):alf a successful product after the MtesterM in repair and clean 3u##estions! +nstall MdoubleM tab in the MtesterM near the end of the trial process in the current product tester for the product stable and steady Res)lts 8!9!)3uccessful, but these methods are only temporary

!*!*H

D)ratio F %&he')le

(he schedules are classified and confidential, are not to be circulated out the company :owever, + am safe to say that the duration to complete this task take few weeks due to people viability for the test run for me to conduct and the to analy%e the defect of the problems

29

!*# !*#*1

PROAECT #C CANDO AND BI44 OB MATERIA4 8BOM9 Tas= Des&riptio

Ca 'o is a typical process plant to provide products that are rarely produced that is not listed in the catalo# with a small chan#e at a time 3uch conditions must be met before the pro$ect Cando Amon# them are! ) 1 -roducts can be reali%ed without modification of new tools or production equipment 2 (he product does not have any ma$or chan#es and ma$or additions and chan#es in the function of the product to avoid risk of quality and production accountin# * Beceivin# a purchase order parts and special packa#in# BOM is a list that contains the item number and quantity of each component in each measurement components 67@ also contains a bill of materials complete and formally structured list of installation components or products

!*#*!

Te&h i()eFMetho'olo5y Use' (he methodolo#y used are same as previous pro$ect < -ro$ect 2 2 2 = 6ut the

setup of 67@ will be /ifferent from the previous pro$ect (he 67@ usa#e of this pro$ect will be as!)

30

Fi#ure! 3hows the 67@ setup process

Fi#ure! 3hows the 67@ structure for this pro$ect

31

Fi#ure! 3hows the 67@ Chan#e on @ass production

!*#*#

Tools Use'C Har'0are a ' %oft0are %pe&ifi&atio s

(he hardware and the software used are similar with the previous pro$ect <-ro$ect 2 2 *=

!*#*@

Pro7le,s a ' %ol)tio s to the Pro7le,s

+f some of the same products produced and mostly composed of equal parts, the -2 may represent a variety of products usin# the J.ariant 67@J 3ometimes the distinction is made due to differences quantities only >ith this problem, the -2 can e1tend the Jsimples 67@J to J.ariant 67@J

32

Fi#ure! 3hows the variable -arts

Fi#ure! shows the .ariant 6om setup

33

Amon# the important aspects before creatin# the J.ariant 67@J is! ) i Cannot create a J.ariant 67@J as J@ultiple 67@J ii Cannot create a J.ariant 67@J of a component or product already has the bomb itself iii (he basic unit of measurement of all the different materials must be the same as the basic unit of measure in the material master record

Fi#ure! 3hows the e1ample of .ariant 67@

34

Fi#ure! 3hows the .ariant 67@ in the -lant

!*#*H

D)ratio F %&he')le

35

36

CHAPTER #C TRAINING$ ?ORK%HOP E %EMINAR #*1 #*1*1 Trai i 5$ ?or=shop E %e,i ar D)ality E ;al)e E 5i eeri 58D;E9 0or=shop

H.2 is the process where we reduce the cost without affectin# the quality of part or product .alue en#ineerin# <.2= is widely used term is industry

Bi5)reC %ho0s D;E 0or=shop pro&ess Blo0*

37

#*1*!

CMI JP4U%+ Co,po e t Mo)l'i 5 I str)&tio Pl)s Trai i 5

(his trainin# is about to have better moulded parts in order produce effective production in the factory +n this trainin# briefly we #et to know how to prepare or mould the parts in order to #et less defect and to increase our mouldin# efficiency (his trainin# is conducted by the mouldin# e1pert @r 7liver @aus<@ouldin# 2n#ineer= those are the steps to optimi%e a better mouldin#! Baw material <Besin= preparation Clampin# -lastici%in# @ould temperature Control +n$ection)Fillin# Chan#e overICushion :oldin# Coolin# .isuali%ation of in$ection 3tability evaluation by part wei#ht

(he full description about this trainin# is attached at appendi1 A

38

CHAPTER @C %UMMARY

@*1

PROAECT E TA%K IN;O4;ED %UMMARY

(he pro$ects which + involved are all stated above 7verall those pro$ects done are very useful for me to be considered as my future references >hen + am in the -roduct 2n#ineerin# team + learnt about the role of a -roduct 2n#ineer /espite that + have learned how to have #ood communication skills, improved my troubleshootin# skills and also learnt about the drawin# on how to read the technical aspect of it Finally + were here to basically know everythin# about a product 2n#ineer works :owever, the tasks + have been doin# in 3chneider are not only pro$ects related $obs, but also thin#s related to -roduct /urin# my time with the -roduct team, + helped to involve myself in the H.2 pro$ect where the pro$ect which involves of cost reduction process 2ven thou#h + spent only few days with the team, + mana#ed to learn about the H.2 system and the method used Furthermore, + will also assist whoever in my department needs my help + was called to assist with another team leader to help them do some test Althou#h help them, they all are very kind)hearted because they never been headache and hesitate to teach me Apart from assistin# my collea#ues, + will also do my own testin# on the products + was first #iven base to test with, learnin# its function and its protection practically by checkin# its /imension and fittin# test, to#ether with the functionality test /espite all those hands on tasks, + will be concentratin# on readin# the products manuals on my free time for the handbooks + am to produce before my internship ends As a conclusion, the trainin#s, pro$ects involvement and task #iven by 3chneider are truly useful + believe that it has #iven me much knowled#e in such a short time

39

@*!

%UGGE%TION BOR IMPRO;EMENT

+t is recommended that the company can or#ani%e trainin# for all the product personnel re#ardin# the internal parts of the switch for e1ample how the internal of a circuit breaker actually operates as all these should be the basic knowled#e for a testin# personnel and they should know well on what they are dealin# with instead of $ust repeatin# the same routine in testin# without understandin# it (he company can also conduct courses or trainin# on the equipment used for testin# as the testin# personnel should be very clear on what equipment they are dealin# with and its ha%ard

40

41

$igure ..1% $A/R Report

$igure ..2% Drawing appro+ed for production

42

43

$igure ..(% $itting test inspection

44

$igure ...% "ompliance test report

45

$igure ..0%Test Report

46

$igure ..1% Test hoto

47

$igure ..2% Trou)leshoot on the 3ase

$igure ..4% 3,5 creation using SA software

48

$igure ..6% 5oulding department on the top +iew

$igure ..17% Assem)l- Su) cell

49

$igure ..11% 5ap to "lipsal )- Schneider Electric 5ala-sia

50

51