List of figure

Figure Figure 3.1: Flow chart of the production process Figure 3.2: Acrylonitrile butadiene styrene (ABS) Figure 3.3: Polypropylene (PP) Figure 3.4: Material storage Figure 3.5: (a) Work In Progress (WIP) parts (b) Drilling machine Figure 3.6: Air leak test Figure 3.7: Assembly process Figure 3.8: Storage and racking system in AHPSB Figure 3.9: Product storage area Figure 4.1: (a) Team building program (b) Safety Awareness Campaign

Page 6 7 7 8 9 10 11 12 12 20

CHAPTER 1

1.0

Introduction

This section will discuss about the scope of the visit, objective of the visit, and the significant of the visit.

1.1

Scope of the visit

For this assigned task we have visited Azman Hamzah Plastik Sdn. Bhd. (AHPSB) production factory area at Lot 3 Seksyen 23 Shah Alam. AHPSB has 3 factories wich are two at Shah Alam; Lot 3 and Lot 10 Seksyen 23 Shah Alam and one at Tanjung Malim Proton City. Due to the scope of visit and limitation of time, our visit only conducted at Lot 3. There is lot of knowledge we were gained from this visit, but we have only focus on the total quality management involved in the company. There were a lot of information about the company but we were only interested to know about the general company profile. In addition, we want to gain experience about the working environment at the factory.

1.2

Objective of the visit

1.2.1 To know the company profile and background. 1.2.2 To gain knowledge about the Total Quality Management of the company 1.2.3 To get an experience on the working environment

1.3

Significant of the visit

Extra knowledge and information about the management organization at AHPSB is the aim of this visit. the information about the company that we got can help us to know the background of the Azman Hamzah Plastik Sdn Bhd (AHPSB). We also can learn on how AHPSB manage their factory in order to developing their company.

We also can enhance our knowledge about the Total Quality Management (TQM) in manufacturing factory since that TQM is the main focus for the visit. AHPSB is using a few technique and method to control the quality of their products. A part from that, we also can learn about the production flow in AHPSBs factory.

In addition, from the visit we can experience about the working environment in AHPSB. This will give us some important information to get prepare before we readily involve in industrial especially in manufacturing factory.

CHAPTER 2

2.1

Literature review

Azman Hamzah Plastik Sdn.Bhd. is a company with major business on doing the manufacturing process of plastic component for an automotive industry using plastic injection molding process plus they also doing the assembly process for the sub component of the plastic itself. This company is one of the most reliable and established plastic component provider for automotive industry albeit the ever competitive Malaysian market, including the surrounding region.

AHPSB major manufacturing process is the plastic injection molding. The process of injection molding is started with the ingot to produce the product. Plastic injection molding is the processes that involve the heating from the materials to the product. To produce good product from this injection, high maintenance of mold is needed as the machine too.

Product that must be assembling using the welding must go through vibration welding leak test. When the test is cleared, product will go through to the assemble area that is conduct by a workers. Workers must do their work followed the schedule that company prepared. Then the product will store to the storage area before it is send to the customers.

CHAPTER 3

3.0 Bhd.

Methodology current relevant operational by the Azman Hamzah Plastik Sdn.

Raw material

Raw material storage

Production

Inspection

Assembly

Storage

Figure 3.1: Flow chart of the production process

3.1

Raw material

Raw material need to check first at the incoming area before move to the raw material storage. At the incoming process the incoming process inspector will inspect the material first to make sure the material fulfill standard requirement. After make the inspection the inspector need to fill the check sheet completely and filing into the monthly material file. After done all the process the raw material will be placed at the storage area. There are many types of raw material that have been used in AHPSB factory. Here are several raw materials which usually use in AHPSB 3.1.1 Acrylonitrile butadiene styrene (ABS)

Figure 3.2: Acrylonitrile butadiene styrene (ABS)

3.1.2 Polypropylene (PP)

Figure 3.3: Polypropylene (PP)

3.2

Raw material storage

Here all material will be placed according to the grade number to improve the production rate. There are hundred type of material need to place correctly according to the material location board. So, it does absolutely reduce the material handler time to find the right raw material. Here, material handler is responsible to fulfill 3 check sheets which are material usage, hopper temperature and raw material order. This entire checks sheets make the management of the raw material was easy to analyze in the future

Figure 3.4: Material storage

3.3

Production

On the production site there are several rule need to follow to achieve the standard quality of product. Here is a critical site to maintain the quality of the product. Production and maintenance need to work together to make sure the product created is achieve the desired. For example on the production working table there are several item need to set up first before start the operation. Leader need to make sure the S.O.P, sample part and tools is already given to the worker. This is because to make sure the products that produce follows the desired specification.

(a)

(b)

Figure 3.5: (a) Work In Progress (WIP) parts (b) Drilling machine

3.4

Product inspection

On this area, products have been inspected manually by a quality control (QC) process technician. QC process technician is assign to check the part randomly every thirty minutes for a whole day. At AHP some product need to pass the leak test especially for a container part. This is because leaking product is not a satisfied the desired quality and need to be replaces before going to assembly section. All the data of the defect must be fulfill in a check sheet.

Figure 3.6: Air leak test

3.5

Assembly

After reach the quantity needed all product is packaging and put in a box. At AHP the orange box means the product need to assemble at the assembly part before stored. Several workers have assigned to make sure product is assembling correctly by follow the S.O.P. Here expert worker is needed because some part needs a skill to assemble especially to use a very technology machine.

Figure 3.7: Assembly process

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3.6

Storage

All products which are ready to deliver are stored at a storage section. The worker is placed all part by follow the labeled to make no defect occur during a delivery day.

Figure 3.8: Storage and racking system in AHPSB

Figure 3.9: Product storage area

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CHAPTER 4

4.1

Quality Assurances

AHPSB was awarded the ISO 9002 Quality Assurance System Certificates in 1996 and QS 9000 Quality System in April 2002, with these stringent procedures and guides in place rigorous control has been established at email state of production, from receiving the material right to the delivery point and ensure that all products comply with customer specifications.

AHPSB worked to be recognized by implementing a quality system according to the world standard. Adherence to this, AHPSB been accredited to ISO/TS 16949 in 2004, QS 9000/ISO 9001 in 2001 and as well as ISO 9002 in 1996. Track records proved that AHPSB always in progress on improving its market identity to be among the best in terms of internationally recognized through a systematic quality level. To ensure precision quality, it is a standard practice and compulsory that every plastic component is checked thoroughly for their quality at every stage of the process and finally by the quality control unit at the quality assurance centre before the products is sent to customers. These been done due to comply with customer specifications and requirements.

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Quality management system is the real backbone that pillars the strength to AHP. ISO 9002 (in 1996), QS 9000 (in 2001) and TS 16949 (in 2004) had been awarded to AHP from SIRIM to recognize the quality system. As to support the backbone, AHP realizes that the need to focus beyond quality in today's modern industrial design of plastic components. This will act as an eye stopper to potential customers.

4.1.1

International Organization for Standardization (ISO)

ISO is the world's largest developer and publisher of International Standards. ISO is a network of the national standards institutes of 163 countries, one member per country, with a Central Secretariat in Geneva, Switzerland, that coordinates the system. ISO is a nongovernmental organization that forms a bridge between the public and private sectors. On the one hand, many of its member institutes are part of the governmental structure of their countries, or are mandated by their government. On the other hand, other members have their roots uniquely in the private sector, having been set up by national partnerships of industry associations. Therefore, ISO enables a consensus to be reached on solutions that meet both the requirements of business and the broader needs of society.

4.1.2

ISO 9000 ESSENTIAL

This section concisely describes the essential features of the ISO 9000 family. The ISO 9000 family of standards represents an international consensus on good quality management practices. It consists of standards and guidelines relating to quality management systems and related supporting standards. ISO 9001:2008 is the standard that provides a set of standardized requirements for a quality management system, regardless of what the user organization does, its size, or whether it is in the private, or public sector. It is the only standard in the family against which organizations can be certified although certification is not a compulsory requirement of the standard. The other standards in the family cover specific aspects such as fundamentals and vocabulary, performance improvements, documentation, training, and financial and economic aspects.
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4.1.3

Certification

ISO does not itself certify organizations. Many countries have formed accreditation bodies to authorize certification bodies, which audit organizations applying for ISO 9001 compliance certification. Although commonly referred to as ISO 9000:2000 certifications, the actual standard to which an organization's quality management can be certified is ISO 9001:2008. Both the accreditation bodies and the certification bodies charge fees for their services. The various accreditation bodies have mutual agreements with each other to ensure that certificates issued by one of the Accredited Certification Bodies (CB) are accepted worldwide. Registration means that the auditing body then records the certification in its client register. So, the organizations management system has been both certified and registered.

4.1.4

Advantages

It is widely acknowledged that proper quality management improves business, often having a positive effect on investment, market share, sales growth, sales margins, competitive advantage, and avoidance of litigation. The quality principles in ISO 9000:2000 are also sound, according to Wade and also to Barnes, who says that "ISO 9000 guidelines provide a comprehensive model for quality management systems that can make any company competitive." Implementing ISO often gives the following advantages: Creates a more efficient, effective operation Increases customer satisfaction and retention Reduces audits Enhances marketing Improves employee motivation, awareness, and morale Promotes international trade Increases profit

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4.1.5

SUMMARY OF ISO 9001:2008 IN INFORMAL LANGUAGE

The quality policy is a formal statement from management, closely linked to the business and marketing plan and to customer needs.

The quality policy is understood and followed at all levels and by all employees. Each employee works towards measurable objectives.

The business makes decisions about the quality system based on recorded data. The quality system is regularly audited and evaluated for conformance and effectiveness.

Records show how and where raw materials and products were processed to allow products and problems to be traced to the source.

The business determines customer requirements. The business has created systems for communicating with customers about product information, inquiries, contracts, orders, feedback, and complaints.

When developing new products, the business plans the stages of development, with appropriate testing at each stage. It tests and documents whether the product meets design requirements, regulatory requirements, and user needs.

The business regularly reviews performance through internal audits and meetings. The business determines whether the quality system is working and what improvements can be made. It has a documented procedure for internal audits.

The business deals with past problems and potential problems. It keeps records of these activities and the resulting decisions, and monitors their effectiveness.

The business has documented procedures for dealing with actual and potential nonconformances (problems involving suppliers, customers, or internal problems).

The business (1) makes sure no one uses a bad product, (2) determines what to do with a bad product, (3) deals with the root cause of problems, and (4) keeps records to use as a tool to improve the system.
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4.1.6

ISO/TS 16949

ISO/TS 16949 emphasizes the development of a process oriented quality management system that provides for continual improvement, defect prevention, and reduction of variation and waste in the supply chain. It provides for the establishment of a common quality management system accepted by leading automotive manufacturers around the world.

4.1.6.1

Application of ISO/TS 16949

A company must first send the application form to SIRIM. From there, a questionnaire must be filled. In the questionnaire, a company must explain about their activities and processes on site. Then, auditor from SIRIM will audit the company. There will be 2 stage of audit that will be done.

Two stages of auditing are required to become registered to the standard: auditing by an external certification body (external audit) and audits by internal staff trained for this process (internal audits). The aim is a continual process of review and assessment to verify that the system is working as it is supposed to, to find out where it can improve, and to correct or prevent problems identified. It is considered healthier for internal auditors to audit outside their usual management line, so as to bring a degree of independence to their judgments.

Under the 1994 standard, the auditing process could be adequately addressed by performing "Compliance auditing. Quality audits are performed to verify conformance to standards through review of objective evidence. A system of quality audits may verify the effectiveness of a quality management system. This is part of certifications such as ISO 9001. Quality audits are essential to verify the existence of objective evidence showing conformance to required processes, to assess how successfully processes have been implemented, for judging the
16

effectiveness of achieving any defined target levels, providing evidence concerning reduction and elimination of problem areas and are a hands-on management tool for achieving continual improvement in an organization. To benefit the organization, quality auditing should not only report nonconformance and corrective actions but also highlight areas of good practice and provide evidence of conformance. In this way, other departments may share information and amend their working practices as a result, also enhancing continual improvement.

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4.2

Employee Empowerment

Employee empowerment is a relatively new management technique that is less hierarchical and gives employees more autonomy and freedom in their job. Employee empowerment also means involving employees in every step of production process. Techniques for building employee empowerment includes Building communication network that include employee; Developing open, supportive supervisors; Moving responsibilities from both managers and staff to productions employee; Building high-morale organizations; and Creating such formal organization structures as team and quality circles.

This concept of TQM was applied in AHSB. Employee empowerment was used in order to increase employees responsibility and authority to make decisions regarding all aspect of product development. From our visit, the technical assistance told that this concept was increasing their education and at the same time controlled the quality of the company product. AHSB was organized so many activities for their employee to increase respect among employees secondary to teamwork. To increase employee education and motivate them AHSB was send their employee to training program. Example of program and activities for AHSB worker: Team Building program on 9th April 2011 Safety Awareness Campaign on 19th March 2011 Certificate Programme for Safety & Health Officer 42nd annual General Meeting (aGM) of the Malaysian plastics Manufacturers association (MpMa)

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(a)

(b)

Figure 4.1: (a) Team building program (b) Safety Awareness Campaign

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4.3

Check Sheet

Check sheet is one of the seven basic quality tools. Data collection can often become an unstructured and messy exercise. Data collection can be simple form in an organized manner and easily convert it into readily useful information. Check sheet function as the presented information in an efficient, graphical format. A check sheet is a table used to systematically register data as it is collected. Check sheets help organize data by category. They show how many times each particular value occurs, and their information is increasingly helpful as more data are collected. Main applications of check sheet include registering how often different problems occur and registering the frequency of incidents that are believed to cause problems. A check sheet is used to: Group data. Collected data should be grouped in a way that makes the data valuable and reliable. Similar problems must be in similar groups. Be creative. Try to create a format that will give you the most information with the least amount of effort. Clearly identity what is being observe. The events being observed should be clearly labeled. Everything has to be looking for the same thing. Advantages of using a check sheet: Easy to use Effective way of displaying data Can identify the root cause of a problem Provides a structure for uniform data collection Can be used to substantiate or refute allegations

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Appendix

21

Appendix:

Figure 1: List of material

Figure 2: List of material location

Figure 3: S.O.P

Figure 4: Organized mold according to color

22

Figure 5: Color code for mould

Figure 6: Machine mapping

Figure 7: Kanban system

Figure 8: Kanban card

23

Figure 9: Dry hopper

Figure 10: Speaker grilled

Figure 11: Production board

Figure 12: Orientation

24

Figure 12: Orientation

25

Parts: Defects BD: Black dot CK: Crack EM: Ejector Mark FM: Flow Mark GM: Gas Mark SC: Scratches SM: Sink Mark ST: Silver streak SS: Short shot WL: Weld Line WRP: Warping WM: White Mark 1

Code: 2 3 4

Mechine: A, B, C, D 5 6 7

Date: 8 9

Total:

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