INDUSTRIAL TRAINING REPORT

SUNNINGDALE TECH SDN BHD

NAME: NG KEE NAIN

COURSE: Bachelor of Engineering (Chemical and Gas)

MATRIC NUMBER: A14KP0129

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ABSTRACT

The industrial training program is one of the requirements for graduation in Universiti
Teknologi Malaysia (UTM) as a part of Bachelor of Engineering (Chemical and Gas). The
objectives of the industrial training is to expose the students to working environment, to
enhance the students knowledge and practical skills, to improve the students
communication skill and to assess students preparedness prior to their joining the
workforce. I was attached to the Department of Quality Assurance where the engineer
known as Customer Quality Engineer (CQE) interacts directly with customers. The people in
our departments mission is to solve problems on the product as requested from the
customer and identify the failure of the product as well also determine whether the product
meets the requirement. After completing my 12 weeks of industrial training here at
Sunningdale Tech Sdn. Bhd., I have done a final report regarding the training program in the
company. The report begins with a brief introduction of the company which includes the
company business segments.

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INTRODUCTION

COMPANY BACKGROUND

SUNNINGDALE TECH SDN BHD IS A ONE-STOP PRECISION PLASTIC ENGINEERING COMPANY

Sunningdale Tech Ltd is a leading manufacturer of precision plastic components. The Group
provides one-stop, turnkey plastic solutions, with capabilities ranging from product & mould
designs, mould fabrication, injection moulding, complementary finishing, through to the
precision assembly of complete products. Boasting a total factory space of more than 3
million square feet, with more than 600 injection moulding machines and a tooling capacity
of 2,500 moulds per year, Sunningdale Tech is focusing on serving four key business
segments automotive, consumer/IT/environment, healthcare and tooling. With
manufacturing facilities across Singapore, Malaysia (Johor), China (Tianjin, Shanghai, Suzhou
and Zhongshan), Sweden (Vxj), Latvia (Riga) and Mexico (Guadalajara), Sunningdale Tech is
strategically positioned to target and capture opportunities in diverse business sectors
globally using 3rd party logistic partners.

PARTNER OF CHOICE

Sunningdale Tech has emerged as an ever more compelling manufacturing partner

delivering greater synergy and value for shareholders through a diversified customer and
product base, new skills and technologies, new geographic markets, stronger management
team and larger talent pool, increased scale and financial strength. The company leverage
our strengths and minimize our gaps, by sharing technology and skills across each others'
facilities. The Group is able to offer customers a strong suite of capabilities across the entire
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value chain, thus bringing us closer to being a Preferred Supplier and Partner of Choice.
Testament to this is our diversified customer base which spans across continents to include
leading American, European, Japanese and Korean multi-national corporations and original
equipment manufacturers

MOVING FORWARD

The aim of the company is to sustain future growth, the Group is continually strengthening
our technical capabilities, investing in infrastructure, broadening our product support
portfolio and geographical reach. Our aim is to provide seamless support to our customers'
global programs and cater to their specific requirements in this rapidly changing market.

Figure 1: Location of Sunningdale Tech around the World

Sunningdale Tech is strategically located in the cost competitive regions serving many Multi-
National Corporations of American, European and Japan origin in the 4 main business
segments, namely Automotive, Consumer / IT / Telecommunications, Healthcare and

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Tooling. The 4 different segments are of very different nature and require attention in
different arena, all of which Sunningdale Tech has taken explicit care of.

BUSINESS SEGMENT

AUTOMOTIVE

In the automotive segment, Sunningdale Tech designs and manufactures decorative plastic
parts such as trim plates for automotive stereo systems, navigation system, air register and
climate controls (also known as bezels), speedometers, steering switches and design covers.
We supply our products to tier one system manufacturers for the automotive industry.
With rising demand for custom-made plastic injection parts and more sophisticated
finishing, the Group continues to leverage on our production technologies such as two-shot
injection moulding, In-mould Decorative and Nd-YAG Laser Marking technologies.
Sunningdale Tech is TS16949-certified, a stringent qualification required for suppliers in the
automotive industry - making us a key plastic components supplier in this sector.
Tapping on the on-going outsourcing trends from the US, Europe and Japan, steadily
increasing demand and long product life cycle, the automotive industry continues to offer
strong growth opportunities for the Group.

MEDICAL

Sunningdale Tech, operating and governing the manufacturing facilities with full compliance
to GMP 21 CFR-Part 820 and ISO quality systems, is dedicated to support the continuously
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evolving needs in healthcare and medical manufacturing. The company take pride in the
people and professionalism to attain highest quality standard, regulatory compliance, and
premium customer service that encompasses a systematic program management from
concept validation till product end-of-life. In continuous effort to provide total solutions to
our valued customers, the company have fully-equipped metrology laboratory coupled with
experienced dedicated resources that will provide excellent customer satisfaction through
best-in-class product quality, information traceability and competitive pricing. With
extensive knowledge and experience in manufacturing class 1, 2 and 3 medical device
components, Sunningdale is well positioned to service the healthcare industry.

CONSUMER / IT / TELECOMMUNICATIONS

The Consumer / IT / Environment industry is a fast-moving and technology-driven sector.

Sunningdale Tech manufactures plastic parts for many consumer products, including but not
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limited to smart cards, consumer electronics & peripherals, telecommunication keypads,
eco-green products, etc. With robust quality practices and a strong manufacturing system
that yields the lowest scrap rate with the best quality standard, the Group strives to
continuously meet the stringent quality and competitive costs expectation of this fast-paced
and high-volume industry. Working closely with the companys technology partners,
Sunningdale Tech employ advanced manufacturing technologies, e.g. RHCM, spin-form
moulding, etc to offer the newest products to the industry. Coupled with the companys
manufacturing capabilities, Sunningdale Tech is well-positioned to tap on the growth
opportunities in this sector. Sunningdale Tech also take pride in the companys sophisticated
high-speed spray painting and UV lines, tempo printing facilities and advanced laser etching
equipment that can handle the high volume demand from our customers. The companys
focus is on producing niche components for the mid to high end market, offering superior
surface finishing as well as rapid tooling to help reduce customers' time to market. With
years of experience serving some of the world's best and Fortune 500 companies in the IT
consumer arena, the Group's collaboration with customer to provide fully automated
turnkey assembly operation of inkjet cartridges is a testament to quality and engineering
standards.

TOOLING

Sunningdale Tech has more than 200 designers and 10,000 sqm of mould manufacturing
area in Singapore and China supporting no less than 2000 moulds fabricated annually. The

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company fully integrated CAD/ CAM designers and highly experienced engineers are capable
of transforming complex product designs to precision plastics using advanced computer
aided design software. Mould Flow Analysis, FEA and 3D-Simulation all provide superior ESI
and DFM services and our sophisticated mould designs are capable of producing plastics
products that meet the requirements of the most stringent customers in the global arena.
On-site concurrent consultancy provides even greater collaboration with clients and
partners. Sunningdale Techs manufacturing facilities are well equipped with advanced tool
room machinery and together with proven track records, system and highly trained staff, we
manufacture high precision moulds that meet requirement of highest quality standards that
will provide trouble-free, high-volume production for the life of the product.

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TRAINING PROGRAMME

1. MACHINE AND TEST

Paint Adhesion Test

Paint Adhesion test is to determine whether the paint will adhere properly to the product
with cross cut test. A crosshatch pattern is made on the product. Detached flakes of coating
are removed by brushing with a soft brush. Adhesion tape is applied over the crosshatch
cuts. Tape is smoothed into places by using a pencil eraser over the area of incision. Tape is
removed rapidly by pulling it out as close to a 180 degree angle.

Classification of Paint Adhesion

Adhesion testing is classified from the scale of 0 to 5 as shown above. The scale for 4 & 5 will
be rejected while the 0, 1 & 2 will be accepted.

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 Figure 2: Process of Paint Adhesion Test

Scratches Detection System

There is always limit in human capabilities. In Sunningdale Tech, all the products have to go
through at least 30 people (operator) from one department to another and finally inspected
by operators in the OQA room. There are still defects on product being sent to customer.
With the use OpenCV (Open Source Computer Vision) and Python language. OpenCV (Open
Source Computer Vision) is a library of programming functions mainly aimed at real-time
computer vision. The library has more than 2500 optimized algorithms, which includes a
comprehensive set of both classic and state-of-the-art computer vision and machine
learning algorithms. These algorithms can be used to detect and recognize faces, identify
objects, classify human actions in videos, track camera movements, track moving objects,
extract 3D models of objects, produce 3D point clouds from stereo cameras, stitch images
together to produce a high resolution image of an entire scene, find similar images from an
image database, remove red eyes from images taken using flash, follow eye movements,
recognize scenery and establish markers to overlay it with augmented reality, etc. Python
was an interpreted, object-oriented, high-level programming language with dynamic
semantics. Its high-level built in data structures, combined with dynamic typing and dynamic
binding, make it very attractive for Rapid Application Development, as well as for use as a
scripting or glue language to connect existing components together. Python supports
modules and packages, which encourages program modularity and code reuse. The Python
interpreter and the extensive standard library are available in source or binary form without
charge for all major platforms, and can be freely distributed. In Sunningdale Tech, the
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camera is use to take pictures of product and dividing the pictures into blocks according to
the number of pixels. Each blocks converts into grey scale and applied Gaussian filter to
reduce image noise and detail. Sobel filter is applied to find gradient magnitude and the
morphological operation applied to process image based on the shape. Join the image
together and fill the hole in the image.

Robot Arm (Vision System)

Figure 3: Robot Arm Checking System (Machine Vision System)

Robotic vision systems consist of one or more cameras, special-purpose lighting, software,
and a robot or robots. The camera takes a picture of the working area or object the robot
will grip and software searches the image for features that let it determine position and
orientation. This information is sent to the robot controller and the programmed positions
are updated. Depending on the application, the camera might be mounted on the robot or
could be in a fixed position within the cell. Calibration is usually needed to relate the vision
system coordinate space to the robot. Many applications only need X and Y-axis information
plus rotation - this is easily extracted from an image. There are several ways to get height
information, such as using stereo cameras. However, in many cases, laser triangulation or
part size are the best options. In laser triangulation, height is derived from the line position
projected onto the target surface and viewed from an angle by a camera. One limitation
though is that either the part or the laser line must move. Alternatively, when the part size is

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known, camera distance can be determined by the parts appearance in size. This technique
is common in vision guided de-palletizing.

Heat Staking Machine

Heat Staking is a joining technology to join two or more parts together where at least one is
made out of plastic. The process is used to melt and deform the plastic material using heat
and force at a set process time. De-forming the plastic is achieved by heating it above the
glass transition temperature and applied pressure. After heating, the materials are cooled
down under pressure again to below the glass transition temperature.

The Hot Bar or thermode, with a defined cavity, comes down on the stud. Force is applied on
the stud and once the required force is achieved the heating process starts. The force
together with the pre-set heat will soften the stud and mould it into the required shape and
at the same time fix the second part. Cool down, still under force, to below glass transition
temperature and finally lift the Hot Bar/ thermode.

Heat staking is used rather than other joining methods is because repeatable, economical
and safe method to form a stud joining two pieces of plastic or plastic and other materials. It
also doesnt require huge design changes and extra material, such as screws, are not
needed.

AIS Machine
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 Figure 4: Assembly Inspection System (AIS)

Inspection tests are usually performed to ensure that there are no defects on the parts or
product. The software used is the same as used by VIS. The software is programmed to
detect the defects on the parts, model number and also missing parts. The camera will snap
picture on the product and compare the product with the master sample saved in the
system. The screen will display OK when the part matches with the master sample and it
will display NG when there is defect or does not matches with the master sample.

Figure 5: Light Testing

Light Test is performed to ensure that there is no light defect or light leakage in between the
buttons. The artwork of the parts is observed thoroughly and the test is performed in a dark
room.

Button Activation Test

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 Figure 6: Button Activation Test Machine

The fixture is connected and place on the PCB board and circuit. The parts will be placed on
the fixture and each button on the part is pressed. If the button is well function, green light
will light up.

Figure 7: Example of Car Audio Product which is used for testing

VIS Machine

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 Figure 8: Visual Inspection System in Laser Department

Based on designs and requirements from customers, the parts of products are transferred to
other departments. The artwork of laser etching on parts of products will last as long as the
substrates surface integrity while the printed artwork will fade as time passes by. Both
artworks performed with printing and laser etching will be checked using Visual Inspection
System. The artwork is checked based on Operation Instruction (OI) and the X-axis and Y-axis
measurement.

2. CONFERENCE CALL

Title: Discussion on the sorting price charges back on SDP with Valeo Shenzhen,China

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The conference call was held on of June with the person in charge, Wendy from China,

Andrew Fong and Sureshen at 4.30pm in Hibiscus room (Meeting room).

Throughout the conference, Andrew had pointed out some undesirable cost charges on SDP.
o The products had been reworked and sent to China before the end of October.
Hence, the sorting cost after that should not be calculated.
o Why there was a need for sending three engineers to Wuhan instead of one? The
cost should not be charge on SDP.

At the end of the conference call, it is to be said that proper usage of language and
communication skill to negotiate with others is needed. It is always not a good idea to have
misunderstanding or conflict with customers. Besides, we should always be well prepared to
deal with others. There is not enough time for us as well as points for us during the
discussion, thus we should be clear in mind in what we want and where is our standpoint.

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 3. STEP DOWN PLAN

QIP STEP DOWN PLAN AND 8D PROBLEM SOLVING

Pareto diagram analysis is a statistical technique in decision making used for the
selection of a limited number of tasks that procedure significant overall effect.

Uses Pareto Principle (80/20 rule) idea that by doing 20% of the work, you can generate
80%of the benefit of doing the entire job.

Figure 9: Pareto Diagram

8D PROBLEM SOLVING FLOW CHART

Most effective in dealing with chronic recurring problems. It is used to discover the
weakness in the management system which allowed the problem to occur in the first
place. The 8D problem solving flow chart is made up of a detection cycle and a
prevention cycle. It emphasize in team synergy.

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 D0 is to prepare and to create awareness which involves education and training,
specialized skills like Fish Bone Diagram, Pareto Analysis and Scatter Diagram. D1 is to
identify the roles and responsibilities of team members. An effective team leader is very
important to lead the cross-functional team in solving problems and implementing
corrective actions based on knowledge, time, authority and skills.

D2 is to define the problem using the concept of 5W (What, When, Why, Who,
Where) and 2H (How, How Many). The problem statement and description must be
determined to make it clear for each member. D3 is to implement and verify interim
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containment action to protect customers from the occurred problems until permanent
corrective action is implemented. Mistake-proofing method, Poka-Yoke is involved to help an
equipment operator to avoid mistakes.

D4 is to define and verify root cause. 4M & 1E factors (Machine, Man, Method,
Material, Environment) are used to reveal root cause. There are two systems of root cause,
occurrence and escapees. Occurrence represents root cause of event which allows the event
to happen and the weakness of the system. Escapees represent root cause of escape point
that allow for the event escape without detection and weakness of detection.

D5 is to identify and verify purposed permanent corrective action. The

effectiveness in each of the proposed corrective action is rated and checked to ensure the
problem is solved. D6 is to implement permanent corrective action by choosing the most
suitable action and contingency plans based on the potential severity of the side effects.

D7 is action to prevent re-occurrence by modifying specifications, update training,

reviewing process flow chart, work instruction and programs. D8 is to communicate result
and recognize team. The results and achievements are published.

4. INSPECTOR PERFORMANCE MEASUREMENT

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Figure 10: OQA Tracking Report by Date

Figure 11: OQA Master Tracking List

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Figure 12: Flow of cases tracking Customer and CSL complaint

In any cases, the company has come out with plans on reducing the number of reject parts
of product but there are still many customer complaints. There are some improvement plans
implemented to boost up the performance of the inspector. OQA supervisor should guide
the inspectors by monitoring them in terms of the standard checking method, view distance,
time through area of inspection, knowledge of product, history of defect parts and so on.
The library on the reject parts with different part number should be enlarged.

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 5. IC/CSL/QAL

PURGING AND SORTING AND THE PURPOSE OF QAL (Quality Alert)

QAL & CAT FORM

- Customer Quality Engineer (CQE) is to create Quality Alert Form and CAT Form upon
confirmation of the customer complaint.

- The CAT form and Master list is to be shared in share folder of the company.

Figure 13: CAT Form (Containment Action Template)

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 Figure 14: Quality Alert Form (Created based on Customer complaint)

INFORMATION FLOW

- CQE is to set on-site briefing on Quality Alert immediately and get acknowledge from
respective person in charge after briefing.

- CQE will send an email on this briefing about Quality Alert to related
departments/person.

- CQE will present the customer complaint in operation meeting.

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PURGING, DISPOSITION AND SORTING ACTIVITIES

Task is to move inventory to MRB location (Physical & System). Disposition whether sorting,
scrap, rework or UAI (use as it is). Production to give the sorting activities result and
verification is to be completed by QA supervisor. If the on hold quantity is SAP system
(company system) is not tally with physical quantity received, QA supervisor is to escalate to
production. People in the production line will have to provide reasonable answer. QA
supervisor is to update the sorting result activities into the CAT form and result. QA
supervisor will need to follow up once result is out. Confirmation of rejected parts after
sorting is to be advice by respective Customer Quality Engineer (CQE) if requested. QA
supervisor or QA engineer will have to follow up on final disposition whether to scrap or
rework or UAI (use as it is) for the rejected part.

Safe Launch/CSL Checklist (CSL)

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 Figure 15: Example of Safe Launch/CSL Checklist (CSL)

Safe Launch/CSL Checklist (CSL) is usually printed out after the latest defect on the certain
product was updated into the CSL Checklist. The document is print out and then is sent to
inspection operator to notify them on the latest defects of the product. In the document, it
usually consists of product picture, trend chart and also defect pictures.

Example of product and equipment used in Sunningdale Tech Sdn Bhd (Automotive)

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Sample Product for Nissan 2Kai Sample product for Fiat

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Rotary Wheel Press Jig Holding Fixture

CONCLUSION

The industrial training program is one of the requirements for graduation in Universiti
Teknologi Malaysia (UTM) as a part of Bachelor of Engineering (Chemical and Gas). Students
will need to undergo internship programme which expose them to the real working
environment. Sunningdale Tech has been growing impressively well these years in order to
achieve its mission and its goals. As manufacturing company, Sunningdale Tech provides an
opportunity for students to work in a real working environment. Sunningdale Tech also
enhance their intellectual, as well as their emotional personalities since students are
involved in companys projects and activities to improve specified engineering aspects of a
companys standard operation procedures. In this training period in Quality Assurance
Department at Sunningdale Tech, a lot of knowledge that do not have in a book. Student had
given a chance to expose to the real working environment and learnt about working life.
Students will experience interactions between engineers and customers where students will
gain knowledge on how to communicate with different type of people. This consider as a
new experience and knowledge where students can never learn it in class. Having a chance
to experience a real life negotiation between people from different companies really gives
student a huge advantage to gain more skills and knowledge. Company supervisors and the
team of engineers really did a good job in helping students to experience the working
environment and allowing us to attend discussion between engineers. Both knowledge and
skills are essentials for student to prepare themselves in the competitive working
environment. After these 12 weeks of industrial training, students have gain knowledge and
skills in the field and also understand the importance of team spirit in accomplishing a
common goal in the company. The rules, regulations, and safety practices in an industrial
environment had been complied with accordingly. Last but not least, student has prepared
prior to join the workforce in the future.

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