10, PERSIARAN INDUSTRI, BANDAR SRI DAMANSARA, 52200 KUALA LUMPUR, WILAYAH PERSEKUTUAN KUALA LUMPUR
HAIZUL HAIQAL BIN ZULFAKA 2011223714
Faculty of Mechanical Engineering UNIVERSITI TEKNOLOGI MARA
SEPTEMBER / 2014
ABSTRACT
Festo Sdn Bhd, located at Bandar Sri Damansara. This company is one of Festo branches worldwide and providing solution for our clients based on information gathered as well as specifications given. Established since 1925, Festo continues to helps any industries for their improvements as well as increasing productivity and effieciency. This report consists the background of the company, Festo and its work culture. The next part is regarding the lesson learnt and experience gained by author together with the main activities and training involved during this Industrial Training Programme. A brief description about the main tasks and jobs done are mentioned in this section. And the last part, author will cover on discussion on sustainability and its common practice. At the end of the report, list of references and appendices are attached. Finally, the report wraps-up with a few closing remarks and conclusions from the experience together with the summary and recommendation for future betterment of Industrial Training Programme.
1.1 History ................................................................................................................. 1 1.2 Structural of main activity .................................................................................. 1 1.3 Objectives ........................................................................................................... 2 1.4 Scope of training ................................................................................................. 2
2.1 Work Ethics ........................................................................................................ 4 2.2 Occupational Safety and Health Environment .................................................... 5
4.1 Overview of the project .................................................................................... 18 4.2 Involvement with project .................................................................................. 18 4.3 Relationship to Mechanical Engineering .......................................................... 21
5.1 Recommendations ............................................................................................. 23 5.1.1 Recommendations for the host company ................................................. 23 5.1.2 Recommendations for the university ....................................................... 23
Figure 1: Festo official logo ........................................................................... 1 Figure 2 : Controller design drawn based on specifications given. ............. 10 Figure 3 : The drawings consists of exterior and interior layour for the panel. ............................................................................................................ 11 Figure 4: Drawing of XY Gantry. ................................................................ 12 Figure 5: Final assembly product. ................................................................ 12 Figure 6 : User manual for CMMS-AS-C4-3A-G2Professional Training ... 13 Figure 7: Preparation of compressed air ...................................................... 15 Figure 8 : Festo air regulator and filter ........................................................ 15 Figure 9 : 3/2 way valve ............................................................................... 16 Figure 10 : Introduction to Pneumatic P111 ................................................ 17 Figure 11 : One of the drawings for Doeka Asia ........................................ 19 Figure 12: Internal part including PLC, valves and servo motor. ................ 20
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1.0 INTRODUCTION
1.1 History
Figure 1: Festo official logo Festo is a privately owned German industrial control and automation company based in Esslingen am Neckar, Germany. Festo was founded in 1925 by Gottlieb Stoll and Albert Fezer. Initially, it manufactured wood cutting tools and later diversified into the automation industry. A noteworthy early product was the first portable, gasoline- poFestored chainsaw.Today, Festo is a leading world-wide supplier of automation technology and the performance leader in industrial training and education programs. Festo has a world-wide presence, in 61 branches and 250 sub-branches. In fact, with a great track record, Festo achieved such a huge achievements by far.
1.2 Structural of main activity
Festo is a worldwide leader in automation and a world market leader in technical training and development. There are 2 main business sector that involved in Festo.
Automation: Solutions for factory and process automation Festo develops pneumatic and electrical drive and control technology for factory and process automation from individual catalogue products to ready-to-install systems. Didactic: Partner for technical education In the field of industrial training and development, we bring together more than 40 years of experience and method skills with a comprehensive range of learning systems. 2
1.3 Objectives
1. To expose the students to actual working culture and industrial practice. 2. To allow the students to extend their theoretical knowledge into practice. 3. To motivate students to practice the right working attitudes and professionalism to increase their employability potential. 4. To provide student with basic skills of technical staff. 5. To enhance student with application skills of engineers and management. 6. To expose students to safe practices and regulations in the industry. 7. To instil the qualities of integrity, responsibility and self-confidence. 8. To assess student ability and competency in their preparation to join the workforce upon completion of their studies in UITM.
1.4 Scope of training
Drawing Electrical circuit, Controller design, Panel Layout Preparation manual and documentation Servo Motor Controller, List of components Assembly process Air Lift control box, Filter Regulator, XY Gantry Software AutoCad, Trilogy, Festo Configuration Tool (FCT), EPlan Testing Vertical Steriliser, Pressure regulator, Pneumatic components Site Visit Nippon Paint Shah Alam, Doeka Asia Subang Jaya Professional Training P111- Introduction to Pneumatics
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2.0 INDUSTRIAL ENVIRONMENT
Aside from the job scope itself, one factor that significantly influences how employees feel about work is the environment. By work environment, everything that forms part of employees involvement with the work itself, such as the relationship with co- workers and supervisors, organizational culture, room for personal development, etc. A positive work environment makes employees feel good about coming to work, and this provides the motivation to sustain them throughout the day.
In Festo, team work is very important and the main element that was practiced since long it was established. They are working on valueing diverse people, ideas, backgrounds and experiences. For example, when completing any project, what author see is everyone in the team working together, discussing, changing and sharing ideas and data even though we come from very differ background from project manager, program engineer as well as system engineer. None of the work is owned by one specific person but instead act as a team in which we are open and accept ideas as well as input from each other. By working in a team, we maintain teamwork even when things are going wrong and we value the teamwork culture. Teamwork is rewarded and gets recognitions from our success in which we get it from teamwork culture instead of doing it alone. Besides, risk and uncertainty can be reduced by this method thus the results would be greater.
During early period, author have been introduced to various departments in the company. Author also experienced the meeting environment for the first time in his life. This experience is priceless to author especially, because author can observed how the meeting were conducted in the real working life. In fact, author learnt a real working life in this company. The situation in this company is very differ compare to university, simly because a different interest. Author have learnt various knowledge, applying all those into this past twelve weeks.
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2.1 Work Ethics
Festo Group is an internationally active family owned company with a long-standing tradition and a high reputation among its business partners and employees. Festo Group emphasizes integrity and has a high standard with regard to ethics and legal compliance. With this Code of Conduct,we acknowledge ourresponsibility towards our commercial and social environment, including our employees working around the world. As this Code of Conduct must be follows by all of Festo staff, failure to follow this code will cause severe consequences for the group and results in disciplinary action against the defendant. The Festo Code of Conduct is an illustration to further explain the provisions of the Code as applied in all the countries in which Festo conducts operations. It does not describe all applicable laws or Festo policies, or give full details on any particular law or policy. It does not constitute legal advice. It does not constitute or create a contract of employment. Festo reserves the right to modify, revise, cancel or waive any policy, procedure or condition without notice and without revision of the Code.
The employees at all times are required to: Conscientiously maintain the highest degree of integrity, Always exercise proper care and judgment Avoid conflicts of interest, and Refrain from taking advantage of our position or exercising our authority to further our own personal interest at the expense of Festo 5
2.2 Occupational Safety and Health Environment
As world leading company, Festo is committed to the highest safety and standards. In line with their commitment, they are enhancing the governance of occupational safety dan health environment ( OSHE) .Our vision of quality and the environment is an attainable image of a worthwhile future and gives meaning to our actions
The main objective is to elevate Festo OSHE performance, reduce business, risks and exposure, and maintain consistency in the implementation of OSHE standards and implementation. Continuous enforcement and consistency in following the Standard Operating Procedure (SOP) recommended are vital in strengthening their OSHE implementation which seeks to establish a pervasive OSHE culture in the renowned corporation.
In strengthening product stewardship practices across Festo, they have begun developing and rolling out implementation plans throughout the downstream business. They have certain measures to manage fatigue at the workplace and a fitness to work guideline has been developed by Festo to better protect the health and safety of their workforce and communities where they operate.
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3.0 INDUSTRIAL EXPERIENCES
There is a quote from E.F. Schumacher, An ounce of practice is generally worth more than a ton of theory, which is enough to describe what author have gone through during this Industrial Training. This is one of the greatest experiences that author have had for the entire life. It is here that author learned and gained so much experience that author could not have from the classroom setting. Author learned what it was like to work in a department with tasks that are due at a minutes notice and how to handle a large workload. This training showed to author, if not highlighted, that author chose the right career path and can happily live with it for the rest of life.
Since author attached with Festo Sdn Bhd, author have learnt various knowledge regrading the automation processes as well as some sort of electrical engineering. This training program helps in order to get into pneumatics system in a larger perspective. Thus,with such a broad knowledge, author believe that this information might helps for future referrals.
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3.1 SKILLS GAINED
3.1.1 Technical Skills
Working with Festo gave author a lot of resources for learning as well as to enhance my skills and improving my knowledge. Apart for the theoritical part, Festo always provide the best technical practice for its staff as its a continueos learning process. As a Festo is a leading company in automation process, thus the quality of our services have been a top priority for all of us. Although the task given may difficult and quite advance, but all the problems and projects have been solved within the timeline given.
3.1.2 Communication Skill
Communication is the foundation of any successful business or organization. We know that the development of communication skills in management is critical for productivity, employee engagement, customer satisfaction and profitability. As an trainee, author knows that the ability to communicate effectively can greatly affect my career development in the future workplace. Author employer highlighted two communication skills needed by all workers: written, oral, and technology.
Written Communication
Oral communication is the mode of choice in most workplaces today; the paper memo is dead, replaced by voice mail, informal conversation, and sometimes E-mail or fax- mail. But two writing tasks still loom before the entry level worker: Writing reports and filling out forms. For example, many companies these days are seeking certification in a variety of world class standard programs, which require extensive documentation. Workers have to fill out reports that ask them to describe exactly what they do and how they do it. In my case, author need to record everything that author did in logbook daily and make a report at the end of Industrial Training.
Oral Communication
We can see that employees still need written communication skills. Yet interpersonal oral communication skills are the ones most prized by employers in the new informal workplace atmosphere. Author could see some of the workers here prefer to test the ability of an intern to follow oral directions. A lot of tasks were actually given orally, which is more effective and more understanding. 8
3.1.3 Time management
The main reason time management is important is to control over the amount of time spent on certain activities thus effectiveness, efficiency and productivity can be achieved. These are some certain steps taken by author in accomplishing the target.
Plan each day Write to do list Punctuality Always come early to the office, meeting or any events. Prioritize the tasks Prioritizing work help in ensuring time and energy are well spent on something truly important instead of unimportant tasks which are time consuming. Take the time needed to produce a quality job Avoid error which can easily waste the valuable time. Do frequent quality check (QC) Take a break when needed Too much stress can results in failure in trying to get organized. When author need a break, author take a walk and make some coffees to refresh my mind.
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3.2.4 Initiative
Showing initiative is a must-do in demonstrating our value at work. It correlates strongly with personal achievement and professional development. It is the act of taking personal responsibility for our own growth, and it is a clear sign of our capacity to develop as a leader. These are among the initiatives that author took during the internship:
Do Your Current Job Well
Employers today are seeking individuals who want to do their job to the very best of their ability every day. Author learned that every task given need to be carried out efficiently and completed within the time frame allocated. This may mean working some overtime, including evenings. For example, all tasks assigned to me during the training are done based on my knowledge limit. Although there is a limit, author tried to take own initiative to gain new knowledge from the engineers here..
Going The Next Step.
It is critically important to do the job well. The key to success is going the next step. For example, as a trainee, author often come into the situation where author need to use a software tool or application. For the first time, it is appropriate to ask for help from the experts, but if it is constantly done, self-development skills will be stop growing and become fading. There are always a few choices whether to read the training manual or refer to the on-line help facility, and attempt to solve this problem on our own. Author is eager to explore new things and think that is why author was destined to be in System Engineering department. To employer, initiative is "going the next step" without being told to do so
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3.2 Training schedule
3.2.1 Drawing
Autocad is one of engineering programe that widely use in industry. This software allows users to draw any types of drawing either is 2D and 3D as well. For instance, author have use this type of programme to complete the task given by authors department. This programme is easy to use, understandable as well as suitable for any type of engineering fields.
Mounting Panel This task was assigned by Design Engineer, Mr Hanizam. As our services required information from our customers, hence we have to customize some of the components that are not available by Festo. Basically, any non-electronics components are customized based on our clients specifications. In fact, we have to collect as much as information needed before proceeding to customization process. Based on our Standard Operation procedure (SOP), all the drawing must be approved by our engineer, before proceeding to any further processes.
Controller Design As a one stop solution provider for pneumatic and automation industries, Festo have provided the best service for their customers. Practically, Festo have to extract our customers idea and will elaborate the ideas by infusing it into our design. For this project, author was assigned to draw control panel (exterior) for one of the project. The drawing have been drawn by using Autocad software and have been approved by our respective enginer.
Figure 2 : Controller design drawn based on specifications given. 11
Panel Layout Design Festo always dealing with pneumatic and automation process, thus we have to come out with a solution,complete with the drawings, just to simplified all the processes. As for this task, author was assigned to draw internal plan layout for one of the panel. This project were completed for B. Braun, company that focussed on pharmaceutical industry.
Figure 3 : The drawings consists of exterior and interior layour for the panel.
3.2.2 Assembly and Testing
As most of Festo components arrived in single piece, thus it needs to assemble before its handover to our customers. Basically, all we have to do is assemble all the components based on the design given. For example,we have to connect all the wiring into the pneumatic system to form electro-pneumatic. Apart from that, some of the assembly process have to be done at customers site due to limitation of space, time as well as extension of our customers project. 12
Figure 4: Drawing of XY Gantry.
Figure 5: Final assembly product.
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3.2.3 Site Visit
As solution provider, Festo always look forward towards their customers. During training program, author have been went a visit to two places, Doeka Asia and Nippon Paint. These were new experiences as author could see how things works as well as gained new knowledge. This experience some sort of eye opener regarding real working life in engineering field.
Doeka Asia This was the first site visit experienced by author. As requested by Mr Liew, author. This project will be elaborate as Industrial Project.
Nippon Paint Author followed Mr Bazli to complete the project. Author have learnt on how to read and key in input-output (i/o) adress. Author was assigned to helps Mr Bazli to complete commisioning process, including to check either the components works properly based on program or not. Some amendments have been changed due to certain problems occured.
3.2.4 Preparation Manual
During this training period, author was assigned by Mr Liew Sip Hoo to prepare a user manual for CMMS-AS-C4-3A-G2 Servo Motor Testing Using FESTO Controller Tool (FCT). Basically, author have done a simulation based on the program for a testing purpose. The software use is Festo Controller Tool (FCT) that provided by Festo. The complete manual is attach in appendix area.
Figure 6 : User manual for CMMS-AS-C4-3A-G2Professional Training 14
3.2.5 Professional Training
Pneumatics is a section of technology that deals with the study and application of pressurized gas to produce mechanical motion. Pneumatic systems, that are used extensively in industry, and factories, are commonly plumbed with compressed air or compressed inert gases. This is because a centrally located and electrically powered compressor, that powers cylinders and other pneumatic devices through solenoid valves, can often provide motive power in a cheaper, safer, more flexible, and more reliable way than a large number of electric motors and actuators.
In major applications compresssed air is used for one or more of the following functions To determine the status of processors (sensors) Information processing Switching of actuators by means of final control elements Carryinng out work
This course emphasized on basic applications of pneumatics mechanism including the symbol, practical as well as other information needed for a beginer. As for author who has no experience in pneumatic program, this course have been a good starting point at all. Author gained a lot of knowledge through this course based on these activities:
Theoritical Part:
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Figure 7: Preparation of compressed air
Figure 8 : Festo air regulator and filter
Inlet Filter Air Compressor Air Reservoir Air Dryer Air Filter Pressure Regulator Air Lubricator Drainage Point 16
Effects of unclean compressed air Corrosion Loosing the port Decrease the efficiency of valve In addition, author have learnt various components for pneumatics from 2/2 valve to pressure sensor. In fact, author have been able to identify the type of valve based on its symbol and its characteristics.
The way to read valve:
Figure 9 : 3/2 way valve
To read the valve, the formula as below:
No of port / No of position
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Practical Author have completed several problem-based questions during the course That is included on applying all the theory into a real life situation. One of the problem is to create a washing machine mechanism by using pneumatic components.
Figure 10 : Introduction to Pneumatic P111
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4.0 INDUSTRIAL PROJECT
DKA is a leading supplier for Industrial Automation solutions. The company was founded in 1966 in Rimbach/Germany as a local machine supplier. Within short DOKA has become a global player with customers in over 50 countries worldwide.Their product range include automated machines and technical solutions for different kind of manufacturing industries. DKA is for example world-wide leading for fully- and semi automatic machines for particular medical products.
4.1 Overview of the project
Doeka Asia is located at Subang Jaya,Selangor emphasizes on manufacturing the machine for their clients. As an expertise, Festo provide a full co-operation with Doeka Asia for their project,namely as Condom Testing Machine With Servo. This machine practically use in order to check the maximum force that can be applied on the condom. The elasticity of the condoms should meet the requirement as stated by our clients. As for this project, Festo are responsible to completing the project, including designing the external and internal parts, electrical circuits as well as commisioning programme.
4.2 Involvement with project
Electrical Drawing
For this project, author was assigned to update electrical drawing based on amendments done by our client. This changes have been made due to several problems occured during testing proces including to improve the efficiency and capability of the machine. As authors background is Mechanical Engineering, this task somehow quite challenging because author needs to understand on how to draw, read and manipulate electrical circuit.
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Throughout the process, Mr Liew helps author a lot in terms of all difficulties happened. In fact, with his guiding, author are able to understand the whole concept of electrical drawing. As Mechanical student, author learnt on theory basis only in the class. By involving this project, author had gain a lot of knowledge regarding electrical components, circuit and connections.
Figure 11 : One of the drawings for Doeka Asia Site Visit During first week of training period, author was assigned by Mr Liew to follow Mr Ryan, to Doeka Asia, Subang Jaya. Practically, author helps Mr Ryan to complete commisioning process of the machine. Through the experience, author have helps Mr Ryan and Mr Liew to complete some wiring works including soldering. Mr Liew explains to author on how the machine works as at the first glance, this was the first time author went to site visit. Based on explainations by Mr Liew, author are able to figure out how the machine works.
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Figure 12: Internal part including PLC, valves and servo motor.
Mr Liew demonstrate regarding the operation of the machine. The software used is from Germany, and its comes with multi-language option. Mr Liew teach Doeka Asia representative to operate the machine. From author observations, the system used is electro-pneumatic. As the visit were on early days, author somehow doesnt have a broad knowledge on pneumatics system, fortunately Mr Liew have teach on PLC, connection of pneumatics components and a lot of new knowledge.
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4.3 Relationship to Mechanical Engineering
In order to relate with Mechanical Engineering field, author believe that these knowledge will be very usefull for a final year of studies. As this project combining electrical, mechanical and pneumatics field, it such a good project that author involved with. There will be a subject called Robotic and Automation that will be apply all these theories including programming PLC, drawing electrical circuits as well as connection between pneumatics components.
To make it short, this industrial project some sort of an eye opener for author to get into pneumatics and electrical field. Author is interested in programming PLC, configuring pneumatics components as well as by hybrid that knowledge with mechanical field. Author is looking forward to configure at least one, and it will be great and interesting if its work.
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5.0 SUMMARY
The past twelve weeks of Industrial Training Programme have been very instructive for author especially. Festo has offered author such an opportunities to learn and develop in many areas. Author gained a lot of experience, especially in the Mechanical and Electrical field. It would help author to choose special topics in the final year of studies. Author learnt a lot from the engineers that author have been working with during Industrial Training especially Mr Liew Sip Hoo and other engineers. All of them are very helpful in sharing their knowledge and experiences. Work ethics, trends, technology and challenges that author may face in the future have been exposed during the period of this training. It is really crucial to get familiar with the industry as it is the first step to build the career in a certain field. In line with the UiTM mission to produce well-rounded graduates who are creative and innovative with the potential to become leaders of industry and the nation, author are able to achieve the objectives set by UiTM in this period of training.
Last but not least, it was a great opportunity for developing personal networking activities and making contacts which may prove of value in the near future and to work with a fantastic team of very hard-working team.
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5.1 Recommendations
5.1.1 Recommendations for the host company
Festo is a great learning company for interns. Author would recommend specifically to the System Solution to keep hiring interns of Mechanical background since it will be a advantages for them. It will help the students to build and improve skills with the knowledge they gained from their studies, as well as strengthen the relationship between industry and educational institute.
5.1.2 Recommendations for the university
Weekly logbook Author suggest that the logbook should be filled weekly instead of daily. Students need to get involve in a team project and other department tasks. So, the workload is heavy, not just for us, but for the supervisor to check and verify. Furthermore, it will steal the time that supposed to be spent to learn new things throughout the internship.
Engagement with intern students Author would like to suggest for UiTM to conduct a few engagement with intern students in their host company throughout the internship to discuss the problem that may be faced and to ensure that the students keep on track to achieve the defined objectives.
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6.0 REFERENCES
1. Peter Croser, Frank Ebel, Pneumatics Basic Level TP 101, Festo Didactic GmBH & Co, 2000 2. G.Prede, d Scholz, Electro-Pneumatics Basic Level TP 201, Festo Didactic GmBH & Co, 1999 3. Doeka Condom Testing Machine With Servo, Festo Sdn Bhd, Department of Solution Engineering, 2014 4. http://www.festo.com/net/lt_lt/SupportPortal/default.aspx?cat=1527&tab=3&s=t