1.

Introduction
1.1 Preface
Industrial training is a main component in the Bachelor of Engineering at university Selangor
A successful Industrial training is essential for the students to be eligible for the degree.
During the Industrial training, the students shall be placed at selected organizations for a
certain period, in which they shall be exposed to the reality of the industrial environment.
This shall also enable the students to prepare themselves for future career endeavour.These
guidelines are prepared as a reference to facilitate the students in various academic programs
Industrial training refers to the placement of a student for a minimum of twelve weeks at an
external organization to experience and apply their knowledge theoretically in the
professional employment. It is also intended for the student to gain exposure in every aspects
of career life socially, culturally, interactions and work conducts.

1.2 Goal
Industrial training aims to elevate the students knowledge and skills in a specific profession
of their respective fields and at the same time produce graduates who are credible, creative
and proficient.

1.3 Objectives
The objectives of the Industrial training are as follows:
i) Enable the students to adapt to the dynamic working atmosphere;
ii) Apply the academic knowledge in managing workplace challenges;
iii) Acquire working experience and develop intellectual knowledge;
iv) Build effective interaction and communication capabilities at all levels;
v) Promote teamwork spirit;
vi) Practise good ethical values and work conducts;
vii) Establish the UniversityIndustry collaboration;
viii) Educate the students in producing related technical report.

1.4 Learning Outcomes

Upon successful completion of the Industrial training, the students shall be able to:
i) apply the knowledge acquired at the organization;
ii) recognize the industry organizational structure and the roles and responsibilities within the
organization;
iii) interact and communicate effectively at all levels;
iv) present critical and innovative opinions with confidence, as well as be capable of
resolving problems professionally;
v) demonstrate excellent ethics and integrity in their work conducts;
vi) work as a team player efficiently;
vii) deliver a comprehensive technical report.

1.5 Scope
The scopes of the Industrial training include but not limited to:
i) System development according to the students programme specialization; in group or
individually. The students should be involved in any of these phases: system analysis, system
design, system coding, system validation and verification, system documentation and system
maintenance;
ii) experience in various line of work through guided tasks such as data collection,
experiment sampling, maintenance and repair, system design and development, resource
management and etc.;
iii) Exposure in management and administration aspects including acquiring overall
understanding about processes and operations of a system;
iv) Involvement in positive activities within the organization

2.0 Organization Background

2.1.1 Company Background

PCO LITE ELECTRICAL SDN BHD was established by our founder Mr Lee Piang Wan
began as a fluorescent ballast manufacturer in 1978. Then, he started diversified into the field
of street lantern, high bay fitting, low bay fitting, floodlight, high pressure ballast, mirror
reflector luminaires, mirror louvres, anti-corrosive fitting, fluorescent batten fitting, diakon
fitting, wire guard fluorescent lamp fitting and many other general-purpose indoor and
outdoor fittings.
After more than 33 years of experience, PCO is now one of the leading manufacturers of
lighting products in Malaysia. We employ approximately 300 workers ( 37% Bumiputra) in
our plant. We cater our market to domestic as well as international markets. Now, PCO has
been acknowledged as a company which is well recognized and accepted by the private
sectors and government department as shown in the project references.
Due to the great demand of our products, we anticipate our present factory which utilized
about 1.5 acres of the total 9.5 acres of land to be running at full capacity any time. In order
to cope with the demand, we had already started planning the expansion in our vast piece of
land. A new factory cum store which was fully built on another 1 acre of land was completed
about 50 meters away from our present factory. This is also part of our progressive expansion.
In additional to these, it has expanded its business to China and the factory in China begun its
productions in the year of 2004. We insist and persist on superb product quality, innovative
design and exceptional value for our customer. These are in lines with our quality policy.

New world of lighting is transforming to the green and energy efficient lighting products.
PCO with 33 years experience as a lighting products manufacturer with globalization vision
is ready with our Green and energy efficient solution products. Our Latest and upcoming
products are designed to fulfil the Green and energy efficient Global lighting needs. We are
rapidly updating our products according to the current market trend.
PCOs new Vision Lighting Solution For your Future not just a sentence but its our
commitment to provide solution for commercial, industrial and residential applications with
our latest lighting design technology for today and appropriate for tomorrow. We believe with
this technology and commitment we can create quality, innovative& reliable original
products. With that aim in mind, in December 2010, we have recently in Putrajaya2G1, 2G2,
EPU, PMU & also in Kettha, retrofitted 18,946 Sets of their old lighting system with our
energy efficient solution of T5 4x14W. The saving is 12% per Fixture which translate to
RM235,000 per year or a savings of RM2 million over 10 years.
Consequently we are investing heavily in R&D to make original patented products which are
designed and made in Malaysia. We have our own fully equipped photometric lab consisting
of goniophotometer, spectroradiometer and luminance meter which enable us to produce our
photometric report including LED to international testing requirements.
The main priority of PCO is to understand and predict the real needs of our customers besides
maintaining innovative and effective lighting solutions in competitive prices. With its
technologies and solutions, PCO has continually opened up new horizons in artificial
lighting.

Our Vision
To be the leading luminaire manufacturer in Malaysia by providing professional lighting
solutions, innovative, efficient lighting design and excellent customer service.

Our Mission
It is PCOs mission to deliver the best and effective lighting solutions for our customers by
constantly upgrading product quality and services according to customer and global trend
needs''

Global Trends

Ongoing urbanization and globalization

Increasing need for energy efficient solutions
Fast growing global illumination market, partly driven by expanding renovation

market
Rapid adoption of LED-based lighting solutions worldwide

Our Reactions

Serve the professional / Projects market

Develop energy efficient solutions like LEDs, TL5
Maximize the profitability of our dealer channel business
Leverage global sourcing

1.2 Brand Philosophy

Having a grand vision in mind, PCO endeavors to spearhead the lighting industry in Malaysia
with a desire to fulfill the ever demanding market requirements. Our brand is highly

environmental friendly and therefore we are endlessly improving the quality, look, feel and
image of our products and the organizational structures to match and exceed consumer
expectations by providing them the uppermost value.
With enormous researches, improvements and headship in design, our brand always seeks to
ensure that all our customers get more than what they have initially expected from us. As a
well-known brand nationwide, PCO is socially and ecologically accountable, inventive and
monetarily rewarding for their employees and shareholders.
Holding solid commitments, our brand endlessly efforts to emphasize our competitive
position and products in the market. Devoted to unfailingly deliver outstanding financial
results, our brand has always retained and sometimes surpassed the expectations of customers
from around the country.

Brand Name
PCO brand is renowned and reliable in this country for numerous reasons. Known earlier as a
ballast manufacturer and now as a leading luminaire manufacturer, PCO had evolved into a
reputable brand in this country. Aggressive marketing strategies are being executed to make
sure that our brand is well known among Malaysians.

Brand Logo
Logos are meant to be the grand ambassador of a company. Our PCO does not vary in this
issue. We had given a good amount of attention to the improvement and enhancement of our

logo. Recently, we came up with a new version of our logo which is currently placed as our
secondary option. This new logo is being aggressively promoted to our customers and
suppliers as it is a proof the modernization that it is taking place at PCO.
Brand identity is a bundle of mental and functional associations with the brand. Companies
are not reasons-to-buy but provide familiarity and differentiation thats not replicable
getting it.

3.0 Organization Background

3.1 Organization Chart
General overview of organization in PCO Snd Bhd

Organization chart according to position

Company General Operation And Products

1. Floodlight Series

2. Street lights

3. Fluorescent Battens

4. Hypermarket lights

3. Department /Unit Attached To

3.1 CNC department

Organization of CNC department

Lee Pak Yuan

(supervisor )

Mohd Amirul Daud

(Programmer)

Mohd Hafis
(line leader CNC
1)

Pak Je Yuan
operator

Balu
Subramanium
(line leader CNC
2)

syam badhur
operator

3.1.1 Task And Responsibilities Of Department

Muhamad Amri
(line leader CNC 3)

Sobhadakar
Operator

CNC basics
Computer Numerical Control (CNC) is a specialized and versatile form of Soft Automation
and its applications cover many kinds, although it was initially developed to control the
motion and operation of machine tools.Computer Numerical Control may be considered to be
a means of operating a machine through the use of discrete numerical values fed into the
machine, where the required 'input' technical information is stored on a kind of input media
such as floppy disk, hard disk, CD ROM, DVD, USB flash drive, or RAM card etc. The
machine follows a predetermined sequence of machining operations at the predetermined
speeds necessary to produce a workpiece of the right shape and size and thus according to
completely predictable results. A different product can be produced through reprogramming
and a low-quantity production run of different products is justified.

Fig.1 CNC Machine

The definition of CNC given by Electronic Industry Association (EIA) is as follows:

A system in which actions are controlled by the direct insertion of numerical data at some
point. The system must automatically interpret at least some portion of this data.
In a simple word, a CNC system receives numerical data, interpret the data and then control
the action accordingly.

3.1.2 Objectives:

To understand the working principle of CNC machines.

To understand the characteristics of the driving systems.
To understand the characteristics of the feedback devices.
To understand the applications of CNC machines.

3.1.3 Elements of a CNC System

A CNC system consists of the following 6 major elements:

a.

Input Device

b.

Machine Control Unit

c.

Machine Tool

d.

Driving System

e.

Feedback Devices

f.

Display Unit

3.1.4 Control panel of cnc machine

3.1.5 Steps and Procedures of handling cnc machine

1)Before start production: ensure that all CNC machines have sufficient oil, check scrap

bucket(if full inform operator to remove) & switch "ON" main switch room.Also check on oil
leakage tank & follow up to clean it.

2)To "ON" machines: Turn "ON" the main switch, release the emergency switch & push the
"ON" button.
3)Before run production: Must zero set the machine by pressing the "JOG" button follow by
"right" & "in" button lastly press the "zero set" button.
4)To start production: Press "memory" button, "reset", "cycle start".
5)Check tooling and program: Press "edit", "reset", "O", program number(ensure tools &
program must match)
6)Learn methods to change tooling(dismantle & assembly of toolings on machine). Ensure
that the tooling upper & lower alignment must be good.

3.1.6 Understanding cutting tools and programme

1)Learn the shapes & sizes of tooling. All programs will have sufficient tooling & stock. If
unavailable, check inside machines.Worn out tooling need to use grinder to modify the
surface.

2)Ensure that machine's display panel must be "OFF" at all time when not in use in ordef to
prolong the lifespan of the display panel & to conserve electricity.

Sample tooling

3)Cables suitability for transferring program to & from computer/machine:

CNC 3000 use green cable.
CNC 2000 use grey cable.
CNC 2048 use diskette.

4)Performing manual test punch on CNC model 3000: Press "jog", press"ON motor",press
-T/+T"(until the tooling number required is facing the front), insert scrapplate & press "test
punch".
5)To perform checking on program whether running smoothly or not, ensure that the "punch
off" button must be activated.
6)Conducted communication with QA whereby 1st piece of product "body pyramid PCPY
recessed" after checked by QA found out that the 1st piece did not match with drawing.
Initiative taken, CNC & QA checked with Lantern section & confirmed the 1st piece was
according to the newest specification. Conclusion: agreed & passed by QA. CNC continue
proceed production.

3.1.7 Transferring program from computer to machine:

on computer, -"start"
-"search"
-"for files & folders"
-key in "dimension"

-"open containing folder"

-"copy"
-go to "comm Exe" folder
-key in address required (ex:"aw"/"zzz")
- "paste"
-go to "short cut to comm.EXE.exe"
-"alt+D"
-key in "CD (address/folder required)"
-"enter" twice
-"alt+S"
-key in "dimension"
-standby cable according to machine
go to machine,-"edit"
-"program"
-"reset"
-"O (program number)"
-"cursor down"
-if "ADRS not found", program can use
-"reset"
-"program"
-"O (program number)"
-"input"
-"read"
go back to computer,-"enter
go back to machine,-press cursor to the right 4 times
until before "/"
-"EOB"
-"insert"
-"reset"

COMPLETE!
Test run 1st piece & send to QA for confirmation.

3.1.8 Transferring program from machine to computer:

on computer,-"comm.EXE.exe"
-"alt+D"
-"CD (address/folder required)"
-"enter" twice
-"alt+R"
-key in "dimension"
-"enter"
go to machine,-"edit"
-"reset"
-"program"
-"O (program number)"
-"input"
-"punch"
go back to computer,-"alt+X"
-"alt+D"
-type "edit (dimension/program)
-"enter"
-"file"
-"save"
COMPLETE!
3.1.9 Performing test punch on CNC 2048,
-"prog"
-"edit"
-"reset"
-"prog"

-"O (program number)", usually use "O000"

-"arrow down" (on upper machine panel)
-"reset"
-go to under "MAT/B1H0.5;"
-set program to perform test punch
-Ex: X150Y150T24 (press "EOB" & "insert")
DX20; (press "EOB" & "insert")
X2500Y650M30; (press "EOB" & "insert")
-"reset"
-"prog"
-"memory"
-"cycle start" (check test punch result).

Performing tool change on CNC 2048,

-"tool change"
-"T16" (tooling position required)
-"EOB"
-"insert"
-"arrow up" (on upper machine panel)
-"cycle start"

Reminder: each time a new program need to use forproduction, after check & exchange the
necessary tooling must check the program wheater running smoothly or not. This can be done
by activating the"punch off" button & press "cycle start".
3.1.10Transferring program from computer to machine:(CNC 2048 using diskette)
on computer, -copy the required program into diskette
go to machine,-insert the diskette
-"read func" (on console panel)
-"arrow down" (on upper machine panel)

-"edit"
-"reset"
-"prog"
-"O"
-"cursor down"
-search for "data not found"
-"reset"
-"prog"
-"O (program number)"
-push "arrow right" button (on screen)
-push "read" button (on screen)
-push "exec" button (on screen)
-refer back to console panel & display
must indicate "push (END) key"
-"reset" on machine panel
-"EOB"
-"insert"
-"reset"
COMPLETE!

3.2 Maintenance Department

3.2.1 Organization chart of maintenance department

Lee Ah Yoke
Plan Engineer

Yusof Abdullah
Senior Engineer

Johan Bin Mat

Senior Technician

kesavan a/l siva

senior engineer

Lee Seng Kok

Technician

Muhamad Zamri
Techniciant

3.2.2 Objective

To emphasize the challenge, skills and experience acquired during training period.
To be part of maintenance team and to participate in activity that carried out on an
asset in order to ensure that the asset continues to perform its intended functions, or to
repair the equipment

3.2.3 Task and Responsibilities Of Department

Machine breakdown procedures

1.
2.
3.
4.

5.
6.
7.
8.
9.

.machine identification type of machine

Inform Head of department and supervisor
Stop all kind of production
Inform technician on duty and problem identification
Type of problem major or minor
First step trouble shooting
Duration needed
Man power
Technician to issues first report and send to engineer
Checking of spare parts and other component
Starting of procedure
Testing of machine
File in record after complete

3.3.4 Type of maintenance work that was carried out

Type /model
Hydraulic motor pump

Problem
Unable to function
Bearing worn out
Rotating fan worn
out

Measures taken
Change new bearings
Change new rotating fan
Minor overhaul

Type /model
Solenoid valve DC24V

Problem

Replace old valve

Measures taken

Change to new valve

Checking of
connecting wires

Type /model
Atlas air compressor

Problem

Measures taken

Over heating
Leakage of hydraulic

Replace new

pipe
Air filter worn out
Need overhauling

hydraulic pipe
Replace new air filter
Change new

hydraulic oil
Internal cleaning and

checking
Replace ne thermostat

Type /model

Problem

Cnc 2000 machine

Rotating cam shaft

chain loosen
Bearing worn out

Measures taken

Replacement of new

bearing
Tighten of chain

4.0 Conclusion
Industrial Training is the important strategy to expose students to real work life situations and
to equip them with the necessary skills that intensify their job acumen. Industrial training
program or training related program can be continuously improved through formal review
and evaluation of its outcome.

A key element in an engineering curriculum is an exposure to the Professional engineering

practice sought through industrial training. Industrial training has traditionally been weighed
as a potent grooming of the professional career of a fresh engineering graduate and it is the
common method of the harvesting skilled engineers. A well-structured industrial training
program as a part of curricula has been recommended, But it is not made compulsory. In
addition to this, other structured industrial projects within the engineering curriculum are
required to strengthen the practical skills of the students.
Training Outcomes and Assessment

Ability to acquire and apply fundamental principles of science and engineering.

Capability to communicate effectively

Ability to identify, formulate and model problems and find engineering solution based
on a systems approach.

Ability to conduct research in the chosen fields of engineering.

Understanding of the importance of sustainability and cost-effectiveness in design and

developments of engineering solution.

Ability to be a multi-skilled engineer with good technical knowledge, management,

leadership and entrepreneurship skills.

Capability and enthusiasm for self-improvement through continous professional

development and life-long learning.

It is the conclusive fact that training is beneficial for students. it evinces that the program has
significantly improved their 'personal attitude', 'Communication skills' and 'Work attitude'. the
experience gained from training sharpen the business acumen of the students and open the
doors of better employment prospects. In essence, the new method of the student's placement
need to be reviewed and improved. However, this study needs an added insight. It is
important for future research to incorporate a wider range of soft skills e.g. Leadership,
teamwork spirit to ascertain the favourable outcomes.