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1.0 BACKGROUND OF COMPANY.

AMAT TEKNIK SDN. BHD was established back in February 1994. They are one of the
pioneer 100% Bumiputra Bolts & Nuts Manufacturer. In the mid year of 1995, they started
production with 2 units of machine.
It has proven since than to become one of the most efficient Bumiputra Fastener
Manufacturer. They cater wide range of local markets needs. Industries such as automotive, metal
base manufacturing, electronics and engineering works. Now with more than 20 units of machine,
they are capable of producing 150MT monthly.
In the beginning of their business, they concentrate in producing forging parts for automotive
and engineering, such as Hexagon Bolt, Weld Bolts and Nuts, Machine Screws and Tapping Screws,
Hexagon Head Screws, Carriage bolts and others. Their current major product is Nuts and Bolts
Weld with various size from M5 to 7/16UNF, Hook Hanger Mufflers from diameter 10mm to 12mm,
Tube Towing Hook, Pin, Rivets, Rollers, Iso-fix, Sleeves, Holder Mounting and etc.
They plan to manufacture high grade and safety parts fasteners with mechanical properties and
conformity to National Standard like BC (UK ), JIS ( JAPAN ), ANSI ( USA ), SIRIM, DIN
( GERMANY ), and etc. In the future, Amat Teknik Sdn. Bhd., intend to produce and market bigger
range product due to domestic market demand and localization program. And at the same time to
improve the quality, service, cost effectiveness and technical innovation for both existing customers
and new customers.
With the current economic vast growth and great demand has promoted Amat Teknik Sdn.
Bhd. to invest on new advance technology in quality testing equipment. With the new technology,
their Automatic sorting machines which electronically detect NG parts is capable to check and sort
600pcs/min. This actually streamlined with the Customers requirement towards ZERO DEFECT.
With the wide range of quality product, Amat Teknik Sdn. Bhd. will widen the market needs and
simultaneously will fulfill our country vision 2020.

2.0 PRODUCT DESCRIPTION

Amat Teknik Sdn. Bhd. manufacturing a mass amount of nuts and bolts. They produced various
type of nuts and bolts with some metal stamping and machining products where it depending on the
customer needs. Here are the list of their products:-

2.1 Nut and Pin


Part Name : WELD

Part Name : ROUND

NUT

WELL NUT

Part Size :M6 - M8

Part Size : M8 - M10

Colour : Plain

Colour : Plain

Part Name :FLANGE

Part Name : DOME

NUT

NUT

Part Size : 7/16 X

Part Size : M12 X

20MM

1.25P

Colour : Black
Part Name : T WELD

Colour :PLAIN
Part Name : CABLE

NUT

ADJUSTER

Part

Size : 7/16 UNF M16

Colour : T/B

Colour :

Plain
Part Name : PIN

Part Name : PIN

RIVET

RIVET

Finished :M7.8 - M10

Part Size : 01 02

Colour : T/B
Part Name :

Colour : Plain
Part Name : PIN

PIN RR SEAT BACK

SELECT

LOCK

Part Size : 8mm X

Colour :T/B

57mm
Colour : T/B

2.2 Bolts

2.3 Metal Stamping and Machining Product

2.4 Other Products

Part Name : SPACER STRUT HOUSE


Part Size : 25mm x 12mm x 25mm
Part No : PW592054

Part Name : NUT PUSH ON SPRING


Part Size : 3mm - 4mm
Part No : PW823856

Part Name : BUSH A, BUSH B


Part Size :10mm - 12mm

Part Name : ROLLER


Part Size : 10.95
Note : Roller Seat

3.0 MANUFACTURING TECHNOLOGIES, PROCESS AND SYSTEMS


At Amat Teknik Sdn Bhd, they have various machines which run at the same time to produce many kind of nuts, bolts and
some other products. These are the machines which owned by Amat Teknik Sdn. Bhd. :
PRODUCT PRODUCT
BIL

MACHINE

1.

ORIGIN

OUTPUT

OUTPUT

SIZE

LENGTH

(MM)

(MM)

Taiwan

M4-M8

8-55

250

90000

AUTO

Taiwan

M8-M16

16-75

240

86400

AUTO

Taiwan

M4-M8

11

240

86400

AUTO

(PCS/MIN)

DAY

CATEGORY

(PCS/DAY)

Bolt Former JBF10B

2.

FORMER
Bolt Former JBF17B

3.

Nut Former NF14B

PRODUCT PRODUCT
BIL

MACHINE

4.

ORIGIN

OUTPUT

OUTPUT

SIZE

LENGTH

(MM)

(MM)

Taiwan

8-12

MAX 150

160

57600

AUTO

Taiwan

8-10

8-55

75

27000

AUTO

Taiwan

6-12

15-50

60

21600

AUTO

Taiwan

M3-M6

5-55

120

43200

AUTO

(PCS/MIN)

DAY

CATEGORY

(PCS/DAY)

NF14B

5.

HEADER

ZH25

6.
ZH20

7.

YH15

PRODUCT PRODUCT
BIL

MACHINE

OUTPUT

SIZE

LENGTH

(MM)

(MM)

Taiwan

M4-M8

8-55

250

90000

AUTO

Taiwan

M4-M8

8-55

250

90000

AUTO

10.

Taiwan

M4-M8

8-55

250

90000

AUTO

11.

Taiwan

M4-M8

8-55

250

90000

AUTO

8.

ORIGIN

OUTPUT
(PCS/MIN)

DAY

CATEGORY

(PCS/DAY)

JBF 10B

9.
THREAD

JBF 10B

ROLLING

PRODUCT PRODUCT
BIL

12.

MACHINE

CIRCULAR
SEWING

13.

ORIGIN

OUTPUT

OUTPUT

SIZE

LENGTH

(MM)

(MM)

Taiwan

0.5 -100

720

AUTO

Taiwan

0.5 -100

720

AUTO

Malaysia

MANUAL

(PCS/MIN)

DAY

CATEGORY

(PCS/DAY)

Cutting 1

MACHINE

Cutting 2

14.

WELDING

IM-300 MIG

The Mechanism of Bolt Former

1. The air clutch brake system has been designed to allow the motor to start from no load
condition, and also able to actuate as "Inching", "Single Stroke" and "Continuous Running". The
main side will always stop at rear position when operating either "Single Stroke", or "Continuous
Running" cycle.
2. The solid cut off die and knife ensures a square cut and clean edges.
3. The cut off cam follower is designed at the center of the cut-off carrier rod to avoid eccentric
force occurred on the cam follower pin and to maintain the rigidity and longevity of the machine.
4. The positive knock-out cam in the punch side was designed by computer to achieve simplicity
and precision Punch side knock out timing coincides with the main slide movement to prevent
spill out of materials from forming die before knock out.
5. The last station rear knock out mechanism can do normal slow motion knock out by simply
changing the knock out cam which is designed for easy replacement.
6. The main machine parts like frame or main slide has been normalized to release the internal
stress after casting. It means to avoid deformation in the future and keep precision forever.
7. All cam diagram in this machine is designed by Computer program and machined through
Machining Center (MC) to gain smooth surface and accuracy.
8. The stability and precision of the main slide is secured by "Overran" designed and the
application of harden alloy steel plates fixed to it will help maintain its precision for a long
period of operation.
9. This machine is equipped with automatic checking device, called Auto-Checker, which will
sensitively stop the machine and to indicate to your operator in case of:

Mal-function of front punch knock out

Mal-function of rear ejection

Overload

Materials short feed

Production reach to counter pre set figure

A limit switch mounted in front of the straightened wheels will automatically stop the machine
when the material runs out.

The cut-off mechanism and its drive have been simplified. The cut-off roller is supported on both
ends for rigidity. The picture also shows the balancing weight on transmission gears.

OTHER FEATURES
1.
The semi finished products are pushed out of the
dies by three knock-out levers which are independently
adjustable. They are controlled by a camshaft underneath.
The third cam can be easily changes for trimmed or
untrimmed bolts.

2.

The main slide extends


to the rear of the
crankshaft for better
balance. The yellow
colored lever is the synchronized positive knock-out lever for the front punches. Since the
motion is synchronized with the connecting rod, it is independent from the position of the main
slide.

3.
The picture shows that maximum working areas is provided. The longitudinal position and the
alignment adjustment for the forming die and the three front punch are independently adjustable.
The mounting and dismounting of the punch is affected by one screw.

4.

Gripper transfer shaft is running freely and smoothly on Liner Bush. The Gripper mechanism can
be swung up for die change and the cassette type gripper slide base can be taken off the machine
for quick set up

PRODUCTION FLOW CHART


ZH 25

FORGING

ZH 40
YH 15

BF
208
BF
178
NF
148

SECONDARY

THREAD

STAMPING

PROCESS

CUTTIN
TAPPIN
G
G

LATHE
DRILLIN
G

S80MT

STORAGE

TR
20
15

Y60MT
CHECKING

TR
25

S110MT

Y80MT

100% MANUAL
CHECKING

BOLT SORTING
M/C
NUT SORTING
M/C

4.0 QUALITY AND SAFETY SYSTEM


Upon our visits to Amat Teknik Sdn. Bhd., we enormously agreed that this company have certain
standard regarding their quality and safety system. They are particular about this matter and look
forward to have a better standard in this area of production in the future.

4.1 Quality Policy and Quality Objective

Quality policy
We are committed to achieve our quality policy which is:
To produce quality products and continuance improvement for customers
satisfactions
Quality objective
We are committed to achieve our three quality objective which are as follow:
To achieve 100% delivery to our customers
To ensure customers complaint not more than 1 per year
To maintain production rejection rate not more than 1% per year

4.2 Quality Control Equipment

AUTOMATIC
AUTOMATIC OPTICAL
SORTING OPTICAL SORTING
MACHINE
MACHINE

3D CAMERA
MEASURING
TENSILE
TESTING
SYSTEM

DIGIMATIC HIGH GAUGE

HARDNESS TESTER

5.0 SUMMARY
The assumption is generally made that more care in maintenance would cure the
problem, or at least prevent it being a danger. Many consider, including bolt and nut,
that the fundamental cause of the problem is design, rather than maintenance, related.
Poor maintenance practices obviously have played a part in many failures, but
manufacturers insisting upon frequent torque re-checks is an indictition that the joint
design on many wheel assemblies is marginal. The inherent variation in bolt and nut
preload as a result of torque tightening can result in the forces acting on some wheel
assemblies exceeding the bolt and nut capabilities to resist them.

6.0 APPENDIX