Industrial Training Report (Omron Malaysia) PDF

INDUSTRIAL TRAINING REPORT
OMRON MALAYSIA SDN. BHD.
MUHAMMAD ADAM ZUHAIRI BIN ZULKIFLI
REPORT SUBMITTIED IN PARTIAL FULFILMENT FOR

THE BACHELOR IN ENGINEERING TECHNOLOGY
(MACHINE TOOLS MANUFACTURING)
MECHANICAL AND MANUFACTURING SECTION
UNIVERSITI KUALA LUMPUR MALAYSIA FRANCE INSTITUTE
BANGI
2019
INDUSTRIAL TRAINING REPORT
OMRON MALAYSIA SDN. BHD.
MUHAMMAD ADAM ZUHAIRI BIN ZULKIFLI
REPORT SUBMITTIED IN PARTIAL FULFILMENT FOR

THE BACHELOR IN ENGINEERING TECHNOLOGY
(MACHINE TOOLS MANUFACTURING)
MECHANICAL AND MANUFACTURING SECTION
UNIVERSITI KUALA LUMPUR MALAYSIA FRANCE INSTITUTE
BANGI
2019
i
DECLARATION
I declare that all the parts of this report are the result of my own work except
for the quotations and references, the sources of which have been
acknowledged in the bibliography.
Date: / / Signature :………………………..

Full Name : Muhammad Adam
Zuhairi Bin Zulkifli
ID Number : 50214217014
ii
APPROVAL
This report was read and verified by:
……………….…………………………... …………………………..
(FARA IZUAN FAREEZ BIN JAFFAR) Date
Company Supervisor
………………………………………. …………………………..
(MOHAMMAD JURAIDI BIN JAMAL) Date
University Supervisor
iii
ACKNOWLEDGEMENT
First and foremost, all praise is to Allah S.W.T for His blessing as helping me
to give guide and strength to keep calm and patient for through this amazing
experience for seeking a bit of knowledge in the manufacturing industry.
Secondly, I would like to express my special gratitude to Mr. Lim Tow Seng
Section Manager of Production Engineering Divison also Mr. Fara Izuan
Fareez my company supervisor for instruct and give me opportunity for doing
the industrial training at OMRON. Also, to Mr. Nazif and Mr. Firdaus, who
guide me during assembly and machining process. Moreover, big thanks to
all the staff in the company. Without their support, I never thought that I would
be where I am right now. Thirdly, distinguished appreciation to my family that
always pray for me and always give encouragement to me finish my
internship. Last but not least, I would like to give a big thanks to MARA for helping
me to continue my study, all the lecturers who have thought me in Universiti Kuala
Lumpur Malaysia France Institute. Only Allah S.W.T can repay for their kindness.
iv
ABSTRACT
Industrial Training, INTRA is one of the most important parts for a complete
learning session for the undergraduates. This is a prior preparation for the
undergraduates to join the industry. OMRON Malaysia Sdn. Bhd. is a
company that focusing in electronics production. During 6 months of the
Industrial Training, there are numerous of knowledge that has been gained
from the staffs of OMRON Malaysia Sdn. Bhd. As an intern I was given a
golden opportunity to try a lot of new thing. The tasks that related to
designing and assembly for G9TA Sub Assembly Machine and G2RS Coil
Terminal Insert where basic knowledge got from UniKL MFI can be apply
during this internship period. The conclusion and recommendation have been
discussed at the end of this report
v
CONTENTS
DECLARATION ii
APPROVAL iii
ACKNOWLEDGEMENT iv
ABSTRACT v
CONTENTS vi
LIST OF ILLUSTRATIONS viii
LIST OF ABBREVIATION ix
CHAPTER 1: INTRODUCTION 1
1.1 OVERVIEW 1
1.2 OBJECTIVE OF THE INTRA 1
1.3 LOCATION OF INDUSTRIAL TRAINING 2
1.4 POSITION GIVEN 3
1.5 MAJOR TASK GIVEN 4
1.6 MID – PED ORGANIZATION CHART 5
CHAPTER 2: COMPANY INFORMATION 6
2.1 COMPANY PROFILE 6
2.2 COMPANY HISTORY 7
2.3 VISION, MISSION AND VALUES OF COMPANY 8
2.3.1 Vision 8
2.4.2 Mission 8
2.4.3 Values 8
2.5 OMRON MALAYSIA MAIN PRODUCT 8
2.6 OMB SAFETY AND HEALTH POLICY 9
2.7 OMB ENVIRONMENTAL POLICY 10
vi
CHAPTER 3: TECHNICAL SECTION 11
3.1 INTRODUCTION 11
3.2 STUDENT TASK 11
3.3 DESIGNING 12
3.1.1 G9TA Sub Assembly Machine 12
3.1.2 G2RS Coil Terminal Insert Machine 12
3.4 ASSEMBLY 14
3.4.1 Spool Supply Unit 15
3.4.2 Platen Jig 16
3.4.3 Press Unit 17
3.4.4 Pneumatic Tube 19
3.5 QUALITY CHECKING 20
3.6 MACHINE WIRING 22
CHAPTER 4: CONCLUSION AND RECOMMENDATION 24
4.1 CONCLUSION 24
4.2 RECOMMENDATION 24
BIBLIOGRAPHY 26
APPENDIX A 27
APPENDIX B 30
APPENDIX C 32
APPENDIX D 34
vii
LIST OF ILLUSTRATIONS
Figure 1. 1 List of Benefits of Industrial Training 2

Figure 1. 2 Location of Company 3
Figure 1. 3 View of Company 3
Figure 1. 4 MID-PED Organization Chart 5
Figure 2. 1 Company Logo 7
Figure 2. 2 OMB Main Product 9
Figure 3. 1 NG Unit Before Modification 13
Figure 3. 2 NG Unit After Modification 13
Figure 3. 3 Index Plate 2D drawing 14
Figure 3. 4 Process Flow During Assembly 14
Figure 3. 5 Spool Supply Assembly Process (Earlier) 15
Figure 3. 6 Spool Supply (Complete Unit) 15
Figure 3. 7 Platen Jig Assembly (Base Unit) 16
Figure 3. 8 Platen Jig Assembly (Top Unit) 16
Figure 3. 9 Platen Jig Assembly (Complete Unit) 17
Figure 3. 10 Press Terminal 1 (Earlier Progress) 17
Figure 3. 11 Press SLSR (80% Progress) 18
Figure 3. 12 Press Terminal 1 (Complete) 18
Figure 3. 13 Press SLSR Unit (Complete) 18
Figure 3. 14 Pin at Press Unit 19
Figure 3. 15 Pin Block at Press Unit 19
Figure 3. 16 Tubing for Press Unit 20
Figure 3. 17 Tubing for Pallet Unloader 20
Figure 3. 18 Platen Jig for Checking 21
Figure 3. 19 Checking Process 21
Figure 3. 20 CMM Report 21
Figure 3. 21 Wire for Bowl and Line Feeder 22
Figure 3. 22 Wire Labelling 23
Figure 3. 23 Wiring Process for Bond Apply Temperature Control 23
Figure 4. 1 Tools/ Equipment Not Placing at Right Place 25
viii
LIST OF ABBREVIATION
2D Two-Dimensional
3D Three-Dimensional
AC Alternate Current
CMM Coordinate Measuring Machine
DC Direct Current
EMC Electronics and Mechanical Components
etc.
GD&T Geometric, Dimensioning and Tolerance
InTra Industrial Training
JIS Japanese Industrial Standard
MID-PED Manufacturing Innovation Department – Production Engineering
Division
mm Millimetre
NG Not Go
OMB OMRON Malaysia Sdn. Bhd.
OMCP OMRON Asia Pacific Pte. Ltd
OMI OMRON Manufacturing Indonesia
OSH Occupational Safety and Health
V Volts
ix
CHAPTER 1: INTRODUCTION
1.1 OVERVIEW
Industrial Training (InTra) is the work experience done during the program of
study that is applicable to professional development prior to graduation. InTra
refers to a program which aims to provide supervised training within a
specific timeframe. The duration of the industrial training is 24 weeks and for
this semester it starts on 15th of July 2019 and end on 27th of December
2019. This training can be carried out either in government organisations or
in the private sector. During the InTra, students will be given tasks by the
company and their performance will be assessed by the company supervisor.
There is also assessment by the lecturer from university where the lecturer
will visit the student’s internship place and the value of the student
performance based on the company supervisor comment and their daily
reports.
1.2 OBJECTIVE OF THE INTRA

The main problem for fresh graduate who just started their work is they learnt
mostly theory knowledge only. These skills only cannot promise the good
performance for them once they enter the industry. Most of the time, the fresh
graduate does not have clue about hardware design and clueless about
terminologies used in the market. This cause a problem when it comes to
hiring. The main purpose of Industrial Training is to prepare students for
future employment in their chosen field. Figure 1.1 shows the benefits of
Industrial Training.
1
Apply technical knowledge and engineering methods to a real life
situations
Hands-on working experience working as professional engineer
Increase students technical knowledge, interpersonal and

communication skills (oral and written)
Observe engineers social skills with others profesional groups
Educate students to be more mature in dealing with the working

challenges
Figure 1. 1 List of Benefits of Industrial Training
1.3 LOCATION OF INDUSTRIAL TRAINING

Company Name : OMRON Malaysia Sdn. Bhd
Registration No. : 13608-T
Company Address : Lot 15, Jalan SS 8/4,
Sungai Way Free Industrial Zone
47300 Petaling Jaya
Selangor,
Malaysia
2
Figure 1. 2 Location of Company
Figure 1. 3 View of Company
1.4 POSITION GIVEN

The position given is Intern and been assigned to the Manufacturing
Innovation Department - Production Engineering Division (MID-PED) that
3
related to my course taking in university which is Machine Tools
Manufacturing that focus on designing, machining and assembly processes. I
have been reported duty under supervision of Mr. Fara Izuan Fareez is an
Engineer and Mechanical Designer. The task as intern is supporting team to
finish their work well.
1.5 MAJOR TASK GIVEN

In the first two and a half months, I was responsible by my supervisor to
assist in the G9TA Sub Assembly Machine project, which is a project for OMI.
While working in this project, I was involved in 3D and 2D design as well in
contributed ideas for one of the units in G9TA project.
In early September, OMI informed that MID was only involved in the
design process and installation process will complete by them. Therefore, my
supervisors get instruction from Division Manager; Mr. Lim Tow Seng asked
me to join the G2RS Coil Terminal Insert project, led by Mr. Nizam.
During this project, I was assigned to draw 2D drawings and to make
revised on 2D drawings I had been checked by Design Leader. For the third
month, I have been joined assembly team to assemble G2RS Coil Terminal
Insert. I had learned how to assemble all unit that use flatness and parallel by
referring to drawing. I also learned how to make use the function of dowel pin
and dowel hole.
4
1.6 MID – PED ORGANIZATION CHART
Figure 1. 4 MID-PED Organization Chart
5
CHAPTER 2: COMPANY INFORMATION
2.1 COMPANY PROFILE
OMRON Corporation is a global leader in the field of automation, sensing and

control technologies where the headquarters in Kyoto, Japan. OMRON is
operating through following segment: a) Industrial Automation, b) Electronics
and Mechanical Components, c) Automotive Electronic Components, d)
Social System and also e) Services and Healthcare.
The Industrial Automation segment manufactures and sells control
components and equipment for factory automation and production
machinery. The Electronic and Mechanical Components segment produces
and merchandises relays, switches, components, and units for amusement
devices, connectors, and combination jogs. The Automotive Electronic
Components segment supplies on board electronic components aimed at
auto makers and automotive component makers. The Social Systems,
Solutions, and Services segment ideals with railway infrastructure, traffic
control, road management, security, environmental solutions, and payment
systems. The Healthcare segment sells digital blood pressure monitors,
digital thermometers, body composition monitors, pedometers, biological
information monitors, and nebulizers.
According to the OMRON report on its website, as of March 2019, the
number of employees in all OMRON's is about 35,090 employees around the
world including OMRON Malaysia Sdn. Bhd. Each country and factory has
their own specialize and type of product which OMRON Malaysia is
specialise in Electronics and Mechanical Components (EMC)
6
2.2 COMPANY HISTORY
Figure 2. 1 Company Logo
OMRON was officially established by Kazuma Tateisi in 1933 as the Tateishi

Electric Manufacturing Company and incorporated in 1948 at Osaka, Japan.
During World War II in June 1945, production has moved to Kyoto after
factory in Osaka is destroyed. In November 1968, company changed the
name to OMRON Tateisi Electronics Co. and established it as company’s
official English name.
October 1988, OMRON has opened their regional management office
for Asia Pacific at Singapore as OMRON Asia Pacific Pte. Ltd (OMCP). For
Asia Pacific, their manufacturing facilities is at Malaysia, Indonesia, and
Vietnam
In Malaysia, known as OMRON Malaysia Sdn. Bhd. (OMB) where
focuses on Electronics and Mechanical Components (EMC). OMB was
established on January 1973 and production began in1974. Being in
operation more than 44 years and located in Petaling Jaya, Selangor, one of
the subsidiaries of OMRON Corporation, Japan.
Business field for OMB is manufacturing of relays, parts and dies that
focuses on tooling parts with integrated manufacturing capability. Most of
their product type focusing on relays, parts used for relays and dies that full
manufacturing ability. OMB facility manufactures electronic components for
advance home appliances and they produce up to 12 million relays unit per
month and is constantly moving to moving towards full automation.
7
2.3 VISION, MISSION AND VALUES OF COMPANY
2.3.1 Vision
OMRON Principles represent our unchanging, unshakeable beliefs.
The OMRON Principles are the cornerstone of our decisions and
actions, they are what binds us together, and they are driving force
behind OMRON’s growth.
2.4.2 Mission
To improve lives and contribute to a better society
2.4.3 Values
• Innovation Driven by Social Needs
Be a pioneer in creating inspired solutions for the future
• Challenging Ourselves
Purse new challenges with passion and courage
• Respect for All
Act with integrity and encourage everyone’s potential
2.5 OMRON MALAYSIA MAIN PRODUCT

OMB has produced 8 types of relay which is G5LE, G6RN, G2RV (Socket),
G2RS, G6D, G2RL, Panel Solution and G5NB. Most of the relays mainly for
Europe, America, Asia and Japan markets. Their electronics components are
produced with the latest technology for advance home appliances, factory
automation and office automation equipment such as refrigerator, microwave
oven, automation machine etc.
8
Figure 2. 2 OMB Main Product
Below is the list of OMRON Malaysia customer’s:

a. Chamberlain Group
b. Whirlpool Corporation
c. Hitachi
d. Electrolux
e. Denso
f. Omron
g. Ingeteam
h. Cabur
i. BSH Hausgeräte (BSH Home appliances)
j. Siemens
k. Fanuc
l. Toshiba
m. Allen Bradley
2.6 OMB SAFETY AND HEALTH POLICY

The management of OMRON Malaysia Sdn. Bhd. is fully committed to
continual improvement. Adopting best industrial practices for prevention of
injuries or illness for our employees and others who may be affected by our
business activities. In order to achieve our aim, we will do the following
principles:
9
• Complying with all applicable Occupational Safety and Health Act,
as well as regulation, guidelines, and codes of practices.
• To preserve a workplace with safe and healthy working
environment for the employees, and those affected by our
business.
• To provide employees with adequate training and necessary
resources relevant to safety and health.
• To do our best to reduce or eliminate and control any occupational,
safety and health risk.
• To promote safety and health awareness programs to employees.
• To communicate safety and health policy to employees and others
interested parties.
• To provide a platform for the employee and their representative for
consultation and participation in OSH programs.
2.7 OMB ENVIRONMENTAL POLICY

In line with the OMRON Principles, we will contribute to realizing sustainable
societies, globally by providing eco-friendly products and services that can
contribute to the global environment and by efficient management resources.
• We will provide eco-friendly products and services that can
contribute to realizing sustainable societies.
• We will continually strive to make improvement to the volume of
greenhouse gas emissions generated throughout the value chain.
• We will make efficient of resources needed in our manufacturing
processes, considering these to be entrusted to our care, in
stewardship by our local and global communities.
• We will work to prevent pollution, recognizing that water, air, and
soil pollution leads to the destruction of the natural environment.
• We will continue in the establishment of our corporate
environmental management system by making continual
improvement, complying with legal requirements, and holding
ourselves accountable by ensuring disclosure of environmental
information to our stakeholders.
10
CHAPTER 3: TECHNICAL SECTION
3.1 INTRODUCTION
Internship or most likely known as Industrial Training (INTRA) in UniKL is
compulsory for all undergraduate students for them to complete their
bachelor’s degree. The purpose of this training is to give students final
preparation before they graduate and join the industries. I chose OMRON
Malaysia Sdn. Bhd. for me to have my 24 weeks of INTRA. I learnt a lot
during my 24 weeks at OMRON Thus, this is the summary of my 24 weeks at
OMRON Malaysia Sdn. Bhd.
3.2 STUDENT TASK

During my 6 months of my involvement in OMRON, the task given is to
support Design and Assembly team.
From the task given by the company, I manage to learn a lot of thing
that can’t get during academic session in designing process such as using
Japanese Industrial Standard (JIS) and the usage of datum with geometric
dimensioning and tolerance (GD&T). Besides designing process, my
department also give opportunity to do assembly task. During assembly task,
I learn the process of assembly start from received part until quality checking.
Besides that, I also had an opportunity to make quality checking and machine
wiring. During quality checking, I have learned about quality checking for
platen jig by referring to Coordinate Measuring Machine (CMM) report
11
3.3 DESIGNING
Designing is one of the important elements I learn in UniKL especially in my
course that I apply during my internship since I involve in two (2) projects for
designing process which is:
a. G9TA Sub Assembly Machine
b. G2RS Coil Terminal Insert
Basically, OMRON is one of the Japanese companies, that all standard
units are based on Japanese Industrial Standard (JIS). In MID-PED, there
are three designer and support by two people from assembly team. For major
design, the project will be design by main designer that are start from concept
design, design review, 3D design, 2D drawing, bill of material list and timing
chart list. Usually support designer will assist designer for minor design and
2D drawing
3.1.1 G9TA Sub Assembly Machine

G9TA Sub Assembly Machine is one of the projects from OMRON
Indonesia (OMI) which it contains two (2) machine with 11 stations. For the
first two (2) months starting the internship, I was train by my supervisor to
practice using company design standard such the usage of datum, GD&T
and the style of measurement. I was assigning by my supervisor to this
project for several stations. For this task, I was asked to make 2D drawing
and some modification for coil take out station, card station, moving block
station, linear index conveyor and unloading unit.
3.1.2 G2RS Coil Terminal Insert Machine

When G9TA agreement between MID with OMI already change, my
supervisor asks me to assign G2RS Coil Terminal Insert project for OMRON
Malaysia (OMB). Project Leader: Mr. Nizam was assign me to make 2D
drawing for 9 unit from 26 units and 3D design for 4 units that need some
modification based on design review. This machine is functioned to insert
terminal at the spool which it has 8 types of terminal for 4 type of spool and
produce 5 types of G2RS product.
12
Figure 3. 1 NG Unit Before Modification
Figure 3. 2 NG Unit After Modification
13
Figure 3. 3 Index Plate 2D drawing
3.4 ASSEMBLY
Assembly process is a process after designing process and part received
from supplier. Figure below shows the process flow during assembly:
Part received
Check dimension
Check surface
roughness
3D design referance
Start assemble
(bottom to top)
Figure 3. 4 Process Flow During Assembly
Starting August, I was given a task for assembly. Therefore, below is

the list of my assembly task:
14
3.4.1 Spool Supply Unit
Mr. Nazif as assembly leader has assign me to assembly spool supply station
which this station is the first station of machine and very important station
because spool cannot be transfer to the conveyor from bowl feeder if spool
supply unit does not assemble well. During this process, if the surface of the
part not smooth or their dimension is not follow to the drawing, the part need
to rework by own for simple modification but for critical part or precision part,
it need to send back to supplier to rework it.
Figure 3. 5 Spool Supply Assembly Process (Earlier)
Figure 3. 6 Spool Supply (Complete Unit)
15
3.4.2 Platen Jig
After finish spool supply unit assembly, I have been giving a task to assemble
platen jig which this jig is self-align jig for X-axis and Y-axis. Platen jig is a
component to hold spool during to terminal insert process along 8 terminals.
Jig is one of the units that must precise and the component at jig must be
tighten very well because this platen jig will be moving on the conveyor that
vibrate. Most of the fastener on the jig is tight using Loctite 243 and Loctite
640 to seal all fasteners with medium bond strength.
Figure 3. 7 Platen Jig Assembly (Base Unit)
Figure 3. 8 Platen Jig Assembly (Top Unit)
16
Figure 3. 9 Platen Jig Assembly (Complete Unit)
3.4.3 Press Unit

Press unit have two types which is Press Terminal 1 and Press SLSR unit.
This unit will press all terminal insert at spool that have been place at front
and back side of the spool. All process is being done at the conveyor on the
platen jig. Press unit process is the most critical unit because after all
terminal is place at the spool, fine pin at the press unit will press all the
terminal at spool to make sure the terminal goes into the available slot before
it transfer to machine 2 for bond apply process.
Figure 3. 10 Press Terminal 1 (Earlier Progress)
17
Figure 3. 11 Press SLSR (80% Progress)
Figure 3. 12 Press Terminal 1 (Complete)
Figure 3. 13 Press SLSR Unit (Complete)
18
Figure 3. 14 Pin at Press Unit
Figure 3. 15 Pin Block at Press Unit
3.4.4 Pneumatic Tube

Besides machine assembly, I also involve in pneumatic tubing installation
where Mr. Nazif give me a task to install pneumatic tubing for both Press unit.
During this installation, length of the tubing need to be consider to make sure
the length is enough to connect with solenoid valve which the area is behind
and below the machine structure and need extra length to prevent the tubing
is rubbing with surface during finishing. After that, I also have opportunity to
install the pneumatic tubing for Pallet Unloader unit where one of the
pneumatic cylinder function as lifter use tube diameter 10 mm that need
pneumatic fitting reducer with diameter 6 mm.
19
Figure 3. 16 Tubing for Press Unit
Figure 3. 17 Tubing for Pallet Unloader
3.5 QUALITY CHECKING

Mr. Nizam as a project leader has given me a task to check the condition of
platen jig during install shoulder screw with bearing either the platen jig is
moving smoothly or not. Based on my checking, during sliding the platen jig,
almost 25 pieces of platen jig need to be separate for further checking. After
the checking progress, information was given to assembly leader; Mr. Nazif
and he ask me to check the CMM report to find the total out measurement.
The good measurement reading must be below than 0.08 mm equivalent to
80 microns.
20
Figure 3. 18 Platen Jig for Checking
Figure 3. 19 Checking Process
Figure 3. 20 CMM Report
21
3.6 MACHINE WIRING
To complete my task during industrial training period, I also got an
opportunity to learn and do some basic machine wiring. Basically all electrical
panels has been done by supplier but the electrical layout is make by
Mr.Ashraf as electrical leader. Mr. Ashraf has given me task to prepare wiring
for bowl feeder that need to connect from electrical panel with bowl feeder
unit. G2RS Coil Terminal Insert machine is using 24V AC/DC. To ease the
wiring work, wire label is used to label the wire either it is Neutral, Live, and
Ground. Both end cable jacket needs to be stripped and use cable string to
avoid stripped wire inside damage. Electrical wire crimp connector is use
before connecting into pin plug male or female connector.
Figure 3. 21 Wire for Bowl and Line Feeder
22
Figure 3. 22 Wire Labelling
Figure 3. 23 Wiring Process for Bond Apply Temperature Control
23
CHAPTER 4: CONCLUSION AND RECOMMENDATION
4.1 CONCLUSION
After going through industrial training for 24 weeks, a lot of experience,
knowledge and exposure that have been obtained. All the exposure was self-
awakening for me to boost my self-confidence to enter the real working
environment. I got a lot of skill that useful and related to mechanical and
manufacturing fields. These skills really motivate me to success when enter
the real world of work.
Training is a compliment to the theory that has been learnt. This is
clearly the concept of science and charity where they have learned without
practice will be lost and will not give anything. I also found that the knowledge
that I need when enter the industry is not only the technical related
knowledge, but also the self-confidence, communication skills and also work
ethics that importance.
4.2 RECOMMENDATION
OMRON is a global company specialise in electronics field, but that does not
mean OMRON has no weakness. As an industry trainee at OMRON, I would
like to suggest that 5S practice enforcement is more practical. This is
because; most of the equipment is not placed in the tool drawer correctly
according to labelling.
24
Figure 4. 1 Tools/ Equipment Not Placing at Right Place
In addition, human resources should reduce paper use rates in

support of the Go Green or Stay Green campaign. This is because; industry
training students need to submit an attendance list each month even though
industry training students have been provided a punch card for attendance
records.
Even though there are still some weaknesses that can be improved
in the future, I conclude that the industrial training program has provided
many benefits to students.
25
BIBLIOGRAPHY
OMRON Asia, 2019, “OMRON History”, https://www.omron.asia/our-history/
OMRON, 2019, “OMRON Principles”,

https://www.omron.com/about/principles/index.html
OMRON Global, 2019, “Basic Corporate Information”,

https://www.omron.com/about/outline/
OMRON Asia Pacific, 2018, “Our Factories”, https://www.omron.asia/our-

business/factories/
OMRON Global, 2019, “OMRON Principles”,

https://www.omron.com/about/principles/index.html
Igaki, Tsutomo; Somekawa, Satomi; Yasui, Kazunori; Iida, Kisho; Chishiro, Ayumi;
Tsukimoto, Tomoyoshi; Fuse, M. (2019). OMRON Integrated Report 2019.
26
APPENDIX A
COMPANY LETTER OF INTERNSHIP ACCEPTANCE
27
APPENDIX B
REPORT DUTY FORM
30
APPENDIX C
COMPANY INDUSTRIAL TRAINEE ATTENDANCE
32
APPENDIX D
TECHNICAL INFORMATION
34
4 5 2D
1 2 3 6 7 3D
A 76.3 ±0.1 A
88
44 12 ±0.1
155 PCD
45°
0.05 A
B
0.05
28
B B
45°
SCALE 1 : 7
163.7 ±0.1
189
66.5
94
30°
60° 47 8-4x M5x0.8 THRU
500
44 44
C 35 35 C
+0.028
+0.013
8 F7
30
28
24
31.3
27.3
25.3
D D
9.8
6 x 6.5 THRU +0.028
AT PCD 155 8 F7 +0.013 THRU A +0.012
4 75.5 77.5 ±0.1 8-4x 4 H7 0 THRU
100 THRU
8-4x M4x0.7 THRU
8x B (1 : 2)
E E
1
APPLICATION QTY
MATERIAL A5052 SCALE
FINISH CLEAR ANODIZE 6µm 1:4
TOLERANCE DESIGNED CHECKED APPROVED INDEX PLATE
3RD
F IT14 9/2/2019 ANGLE
F
ROUGHNESS MID-PED
Refer to the
outside of
Refer to the
outside of SHEET
DRWG
NO. X010808A
12.5
[ UNIT : mm ] SYM DATE E/C CONTENTS E/C NO. SIGN NIZAM the frame the frame 1/1 DESIGNED FOR G2RS COIL TERM INSERT- INDEX TABLE
DRAWN ADAM A3
3 4
1 2 5 6
4x 3.4 THRU
6.5 3
A (BACK SIDE) A
+0.010
10 x 3 H7 0 THRU
108 ±0.1
78 ±0.1
56 16
12 x M3x0.5 THRU 64 ±0.1
2 - C2
50 ±0.1
20 ±0.1
A
B B
20
38.5
26
55
20
17
12.5
7.5
7
C 14 30 40 30 C
6.5 15 15 15 25 15 15 15 6 0.05 A
128
8x 4.5 THRU
8 4
1
[ UNIT : mm ] APPLICATION QTY
MATERIAL SS400 SCALE
FINISH ELECTROLESS NICKEL PLATING 3~5 1:1

D TOLERANCE DESIGNED CHECKED APPROVED
LOCK BASE D
3RD
IT14 10/2/2019 ANGLE
X010803A
Refer to the Refer to the DRWG
ROUGHNESS MID-PED SHEET NO.
outside of outside of
12.5
SYM DATE E/C CONTENTS E/C NO. SIGN NIZAM the frame the frame 1/1 DESIGNED FOR G2RS COIL TERM INSERT-LOADING INDEX
DRAWN ADAM A4
3 4
1 2 5 6
180
10 60 100 15 150
30 120 3
15
3
A A
107.5 ±0.1
50 45
105
125
6 x M6x1.0 THRU A-A 4x 15 THRU

+0.012
2 x 5 H7 0 THRU 0.05
0.05 A
B B
15
3 x M4x0.7 THRU
(BOTH SIDE)
102
±0.1
388.5
102
A A NOTE:
C C
114.5
1) WELDING CONSTRUCTION
2) WELDING TOGETHER WITH RECTANGULAR
HOLLOW (100x75xt3)
3) MILLING PROCESS AFTER WELDING
95
15
30 75
10 100 135
A 180 1
MATERIAL SS400 t16 , RACTANGULAR HOLLOW (75x100xt3) SCALE
FINISH ELECTROLESS NICKEL PLATING 3~5µm 1:5

P&P STAND D
3RD
IT14 9/2/2019 ANGLE
X010786A
12.5
SYM DATE E/C CONTENTS E/C NO. SIGN NIZAM the frame the frame 1/1 DESIGNED FOR G2RS COIL TERM INSERT- LOADING INDEX
DRAWN ADAM A4
3 4
1 2 5 6
M3x0.5 6
68.5
2.5
THRU
A 9 A
NOTE 1 100 +0.022 5
10 40 40 4 F7 +0.010 THRU
3
+0.022
+0.010
80
±0.1
4 F7 45 3x 5.5 THRU
19.5 1
7
2 x (R)
24.9
30
51
8
2 x (R)
80
80
150 ±0.1NOTE 1
+0.2
+0.1
B B
10.2
4 x M4x0.7 THRU
8.5 THRU
58
170
THRU
30
+0.022
+0.010
2 x (R) 2-2x M4x0.7 8
(BOTH SIDE)
6 F7
C C
NOTE:
1) TOLERANCE VALUE IS APPLICABLE
+0.025 34.5 1 C20 AT DOWEL PIN HOLE ONLY
40 H7 0 THRU
13 74 +0.022
2x 5.5 THRU ALL 31 58 6 F7 +0.010 THRU
10 5.5
1

MOUNTING PLATE D
3RD
IT14 17/7/2019 ANGLE
X010771A
12.5
SYM DATE E/C CONTENTS E/C NO. SIGN CKW(NIZAM) the frame the frame 1/1 DESIGNED FOR G2RS COIL TERM INSERT - BRIDGE CONV
DRAWN ADAM A4
3 4
1 2 5 6
6
A A
4x 3.4 THRU
6.5 3
(FROM BOTTOM)
128 +0.010
10 x 3 H7 0 THRU
108 ±0.1
78.2 ±0.1
2 - C2 64 ±0.1
50 ±0.1
20 ±0.1
B 12x M3x0.5 THRU B

38
25
55
18
13
C 8x 4.5 THRU C
7
8 4
56 16
14 30 40 30
6.5 15 15 15 25 15 15 15
1
FINISH ELECTROLESS NICKEL PLATING 3~5 1:1

BASE D
3RD
IT14 9/2/2019 ANGLE
X010554A
12.5
SYM DATE E/C CONTENTS E/C NO. SIGN NIZAM the frame the frame 1/1 DESIGNED FOR G2RS COIL TERM INSRT-PART LOCK MC2
DRAWN ADAM A4
3 4
1 2 5 6
A A
+0.022
8x 3.5 THRU
5 F7 +0.010 THRU 2 x R5 6.5 4
2 x M4x0.7 THRU
6 - C5
2 x (R)
20
B B
35
90
52
31
45
20
THRU
10.5 ±0.1
NOTE 1
15 50
7.5
+0.022
+0.010
23.5 1 10
31.5 ±0.1
5 F7
74 32 +0.010
C 80 20 2x 3 H7 0 THRU C
90 ±0.1 NOTE:
4x 5.5 THRU
10 5 110 1) TOLERANCE VALUE IS APPLICABLE AT
(BACK SIDE) DEWEL PIN HOLE ONLY
1
MATERIAL A5052 SCALE
FINISH CLEAR ANODIZE 6µm 1:2

P&P LM GUIDE PLATE D
3RD
IT14 23/08/2019 ANGLE
X009984A
12.5
SYM DATE E/C CONTENTS E/C NO. SIGN FAREEZ the frame the frame 1/1 DESIGNED FOR G9TA SUB ASSY MC - UNLOADING UNIT
DRAWN ADAM ZUHAIRI A4
3 4
1 2 5 6
92
3 - C10 28 30
15 ±0.1
44 ±0.1
A 0.05 B A
0.1
65
0.05 A
R10 A
+0.012
75
283
B 4x 4 H7 0 THRU B
10 x 5.5 THRU
200
75
28
90
±0.1
39.5
53.5
35
B
C 70.5 7.5 C
65 100 8
6x 5.5 THRU 80 80 10
10 6 180
1

P&P MOTOR PLATE D
3RD
IT14 23/08/2019 ANGLE
X009976A
12.5
SYM DATE E/C CONTENTS E/C NO. SIGN FAREEZ the frame the frame 1/1 DESIGNED FOR G9TA SUB ASSY MC - UNLOADING UNIT
DRAWN ADAM ZUHAIRI A4
3 4
1 2 5 6
51
M4x0.7 15
A A
SCALE 1 : 2
R0.2max
R0.2max
31°
31° 31°
B 31° 4 ±0.015 B
+0.015
M4x0.7 15 10 H7 0 THRU
51
+0.1
01.8
57
53
24
53
C C
+0.1 +0.1
2.2 9 0 2.2 9 0
0.1 A 13.4 42.2 0.1 A
69
3
MATERIAL SUS 304 SCALE
FINISH - 1:1.5
Drive Pulley D
3RD
IT 14 12/07/19 ANGLE
X009213A
12.5
SYM DATE E/C CONTENTS E/C NO. SIGN CKW(NIZAM) the frame the frame 1/1 DESIGNED FOR G2RS Coil Terminal Insert - Bridge Conv
DRAWN ADAM A4
3 4
1 2 5 6
A 0.03 A A
24.5
13 ±0.1
20.8
24.8
A
R0.2 max.
2x 3.5 THRU +0.010
8 7 2x 3 H7 0 THRU
4 15
B 23 B
8
5 13 4x(R)
6
4.5 4.5
6
0.05 B
33
21
C C
15
6
B
1
FINISH ELECTROLESS NICKEL PLATING 3 ~ 5 µm 1:1

MOV. BLOCK ESCAPE STAND 2 D
3RD
IT14 2/08/2019 ANGLE
X008978A
12.5
SYM DATE E/C CONTENTS E/C NO. SIGN FAREEZ the frame the frame 1/1 DESIGNED FOR G9TA SUB ASSY MC - MOVING BLOCK
DRAWN ADAM A4
NO INFOPOINT
G2RS COIL TERMINAL INSERT (BOM LIST)

REV. DRW NO. PART NAME MATERIAL FINISH/TREATMENT QYT REMARKS
POWDER COATING
B X009312 STRUCTURE_2 SS400 50x50xt3.2 1
PR11/960/CS3
POWDER COATING
B X009315 STRUCTURE 2-1 SS400 50x50xt3.2 1
PR11/960/CS3
B X009316 BASE PLATE 2-2 SS400 ENP 3~5µm 1
A X009318 BASE PLATE 2-4 SS400 ENP 3~5µm 1
A X009323 BASE PLATE 1-4 SS400 ENP 3~5µm 1

POWDER COATING
B X009324 STRUCTURE_1 SS400 50x50xt3.2 1
PR11/960/CS3
B X010835 ISLAND PLATE SS400 ENP 3~5µm 44
A X010836 PLATE 2 SS400 ENP 3~5µm 10
A X010837 PLATE 3 SS400 ENP 3~5µm 13
A X010838 PLATE 4 SS400 ENP 3~5µm 4

POWDER COATING
A X010839 BOTTOM PLATE 1 SPCC t2.3 1
PR11/960/CS3
POWDER COATING
PR11/960/CS3
POWDER COATING
PR11/960/CS3
POWDER COATING
PR11/960/CS3
A X009619 ELB MOUNT BRACKET SPCC t3.0 ENP 3~5µm 1 NEW ADDED
A X009621 ELB MOUNT BRACKET SPCC t3.0 ENP 3~5µm 1 NEW ADDED
SPEED CONTROLER
A X010985 SUS304 t2.0 - 5 NEW ADDED
BRACKET
A X010986 EMERGENCY BRACKET SUS304 t3.0 - 5 NEW ADDED
A X010987 APU MOUNT BRACKET SPCC t2.0 ENP 3~5µm 3 NEW ADDED
A X010988 VALVE PLATE SPCC t3.0 ENP 3~5µm 5 NEW ADDED
A X010993 L PLATE 2 SPCC t3.2 ENP 3~5µm 3 NEW ADDED
A X010994 MAGNET CATCHES MOUNT SPCC t3.2 ENP 3~5µm 16 NEW ADDED
ASSEMBLY DRAWING
Serial No.: XXXXXM

P/J No.： XXXXXX (SI-1)
DESIGNED CHECKED APPROVED G2RS
MID-PED MID-PED MID-PED COIL TERMINAL INSERT
22/08/2018 23/08/2018 23/08/2018 INDEX CONV.
NIZAM HASHIKAWA LIM FAB Parts list (CATALOG PARTS)
SHEET NO. DWG.NO
SYM DATE E/C CONTENTS SIGN 3 ／3 MB11111-Z00 -1

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INDUSTRIAL TRAINING REPORT

OMRON MALAYSIA SDN. BHD.

MUHAMMAD ADAM ZUHAIRI BIN ZULKIFLI

REPORT SUBMITTIED IN PARTIAL FULFILMENT FOR

MECHANICAL AND MANUFACTURING SECTION

UNIVERSITI KUALA LUMPUR MALAYSIA FRANCE INSTITUTE

OMRON MALAYSIA SDN. BHD.

MUHAMMAD ADAM ZUHAIRI BIN ZULKIFLI

REPORT SUBMITTIED IN PARTIAL FULFILMENT FOR

MECHANICAL AND MANUFACTURING SECTION

UNIVERSITI KUALA LUMPUR MALAYSIA FRANCE INSTITUTE

Date: / / Signature :………………………..

This report was read and verified by:

experience for seeking a bit of knowledge in the manufacturing industry.

Section Manager of Production Engineering Divison also Mr. Fara Izuan

guide me during assembly and machining process. Moreover, big thanks to

be where I am right now. Thirdly, distinguished appreciation to my family that

always pray for me and always give encouragement to me finish my

LIST OF ILLUSTRATIONS viii

1.2 OBJECTIVE OF THE INTRA 1

1.3 LOCATION OF INDUSTRIAL TRAINING 2

1.4 POSITION GIVEN 3

1.5 MAJOR TASK GIVEN 4

1.6 MID – PED ORGANIZATION CHART 5

CHAPTER 2: COMPANY INFORMATION 6

2.1 COMPANY PROFILE 6

2.2 COMPANY HISTORY 7

2.3 VISION, MISSION AND VALUES OF COMPANY 8

2.5 OMRON MALAYSIA MAIN PRODUCT 8

2.6 OMB SAFETY AND HEALTH POLICY 9

2.7 OMB ENVIRONMENTAL POLICY 10

3.2 STUDENT TASK 11

3.1.1 G9TA Sub Assembly Machine 12

3.1.2 G2RS Coil Terminal Insert Machine 12

3.4.1 Spool Supply Unit 15

3.4.2 Platen Jig 16

3.4.3 Press Unit 17

3.4.4 Pneumatic Tube 19

3.5 QUALITY CHECKING 20

3.6 MACHINE WIRING 22

CHAPTER 4: CONCLUSION AND RECOMMENDATION 24

Figure 1. 1 List of Benefits of Industrial Training 2

1.2 OBJECTIVE OF THE INTRA

Hands-on working experience working as professional engineer

Increase students technical knowledge, interpersonal and

Observe engineers social skills with others profesional groups

Educate students to be more mature in dealing with the working

Figure 1. 1 List of Benefits of Industrial Training

1.3 LOCATION OF INDUSTRIAL TRAINING

Figure 1. 3 View of Company

1.4 POSITION GIVEN

1.5 MAJOR TASK GIVEN

Figure 1. 4 MID-PED Organization Chart

2.1 COMPANY PROFILE

OMRON Corporation is a global leader in the field of automation, sensing and

Figure 2. 1 Company Logo

OMRON was officially established by Kazuma Tateisi in 1933 as the Tateishi

2.5 OMRON MALAYSIA MAIN PRODUCT

Below is the list of OMRON Malaysia customer’s:

2.6 OMB SAFETY AND HEALTH POLICY

2.7 OMB ENVIRONMENTAL POLICY

3.2 STUDENT TASK

3.1.1 G9TA Sub Assembly Machine

3.1.2 G2RS Coil Terminal Insert Machine

Figure 3. 2 NG Unit After Modification

Figure 3. 4 Process Flow During Assembly