CHAPTER 1

INTRODUCTION

1.1 Overview

Industrial training is a compulsory for all student in PTSS in order enable

them to graduate. Before doing any task, training is the first step. Everyone

had to be train before the person can perform well in any task or work. So

training also plays an important role in the life of students.

The main purpose of this industrial training is providing students get into the

real industrial environment in order to get the experience in hands on the

machine and practical knowledge. With the knowledge and experience

gained on this industrial training, it can help students to beef up the resume

and make it valuable industry contacts that are important to get the ideal job

upon graduation. In addition, the industrial training also helps student to

improve their skills and knowledge in order to handle any kind of problem in

their relevant field.

As a DTK student, student can experience the real electronic world while

training at industrial. With that, student can compare the real scenario with

the theory that we learned in polytechnic.

This report is my result of 5 months internship in Jabil Circuit and also

prepared as a requirement of completion in DTK program of polytechnic. All

the procedures and theory that I had learned is record in this report.

1
1.2 Objective Of Industrial Training

This industrial training is needed to let students to learn the gap between the

knowledge learn from classroom and the real working situation in order to

success in the future. Below are few of objective of internship:

i. To be able applying the knowledge and skills that learned from

classroom to work.

ii. To gain a broader perspective and knowledge of the industry,

companies and careers in respective professions.

iii. To appreciate the reality about the work environment and the

importance of work values and culture.

iv. Provide opportunity for students to learn in problem solving with

engineering skills.

v. To help in improving students responsibilities.

vi. To provide students the opportunity for develop attitudes

conducive to effective interpersonal relationships.

vii. To help students construct self-confident.

viii. Provide students the opportunity to test their interest in a particular

career before permanent commitments are made.

1.3 Objective of report

All the students of Polytechnic need to submit the final report to UPLI as a

term and condition of industrial training program after finish their internship
2
 in order for them to graduate. The objectives of report carried out for the

purpose below:

i. Shows the result from industrial training that included what

students had learned in this training.

ii. To help students in explaining the experience about the internship.

iii. To train student in providing a report with standard and quality.

iv. Assess the ability of a student is preparing a report in the specified

time.

v. Recorded duties and tasks can be a guideline for the junior or

someone who will take over the job.

vi. Can be the reference during the learning period of students.

vii. Through writing a report, students can learn more details in the job

range.

1.4 Importance of industrial training

Below are some interests such as industry training show why it is

importance:

i. Increasing knowledge about the technical and computer skills that

practiced in daily work.

ii. Gain communication skills, management, develop skill, creativity

and sharing ideas with others in the factory.

iii. To expose students to a different environment during learning and

encourage students to always give their best in any situation.

iv. Students are able to measure the abilities and capabilities through

the comments from the supervisor.

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 v. Due to expose students to the challenges of work to make the

students stronger and wont give up easily.

vi. To get qualify for the award of a Certificate or Diploma to

students.

vii. Can enhance the resume of students.

Industrial Training helps in increasing the knowledge and skill of a

student for doing a particular job. The most important of the industrial

training is to expose student on practical engineering field. Through this

expose, student will better understanding about engineering practical in

general and the possible problems that will be occur.Its can be increase

the knowledge and experience of a student needs.

4
 CHAPTER 2

COMPANY BACKGROUND

2.1 Introduction and history of JABIL Circuit

Figure 2.1 Logo of Jabil Circuit

Jabil Circuit is a US based global manufacturing services company. Its

headquarter is located in St. Petersburg, Florida, it is one of the largest

companies in Tampa Bay. Jabil has 90 facilities in 23 countries and a

total count about 175,000 employees worldwide.

The company was founded in 1966 by 2 founders that is James Golden

and Bill Morean. Hence, the name of Jabil is created by the names of

James Golden and Bill Morean. Since its incorporation in 1969, the main

product was printed circuit boards (PCB). About 10 years later in the

1980s the company started making parts for PC companies such as Dell,

and continued through the mid 1990s. The company went public in year

1993. Then in 1998, Jabil began trading publicly on the New York Stock

Exchange (NYSE) under ticker symbol JBL.

5
 The current Jabils president is William E. Peters and William D. Muir, Jr

as the COO respectively, was appointed on 1 March 2013. Both had

been with Jabil more 20 years. On the same day, Mark Mondello was

appointed to CEO, replacing Timothy Main, who was elected Chairman

of the Board of Directors.

Jabil customers are including including healthcare, life sciences, clean

technology, instrumentation, defense, aerospace, automotive,

computing, storage, consumer products, networking and

telecommunications. Its services include design engineering,

manufacturing and supply chain services for the EMS and consumer

industries; and materials technology services (plastics, metals,

automation and tooling).

2.2 JABIL Penang location

Figure 2.2.1 Jabil Penang plant 1

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 Jabil Penang is nestled in the south east part of the tropical island of

Penang in Malaysia. First incorporated in 1995, this 20+ year old site was

the first Jabil site in Asia.

Penang is often referred to as the Silicon Valley of Malaysia and the free

trade zone that Jabil Penang is located in dates its origins to 1972. The

benefits of this long-with standing site includes a mature and world class

supply chain, logistics, accommodation, skilled labor and business-

friendly local authorities.

Figure 2.2.2 Jabil Penang location map

2.3 Company activities

Jabil is involved in design engineering services. The company has

industrial design services that concentrate on designing the look and feel

of plastic and metal enclosures that house printed circuit board

assemblies and systems. Mechanical design services of Jabil include

7
dimensional design and analysis of electronic and optical assemblies.

Computer assisted design from Jabil includes printed circuit board

assembly design testing and verification and other consulting services.

2.3.1 Design Engineering

Jabil has an industry-specific design team for each of the

industries that they supply including computer and storage, digital

home, healthcare and instrumentation, point of sale, and mobile.

Jabil has assisted many Fortune 500 companies with design and

engineering including inventing the Sandy Creek, a dual Intel

Xeon E5-2690 (Sandy Bridge Romley-EP) based reference design

for use in customer applications. Jabil also assisted Cisco with

value engineering by placing RFID in circuit boards to store data

about the host board.

2.3.2 Supply chain and logistics

Jabil provides supply chain and logistic services. These services

include electronic sourcing, virtual / vertical mechanics, logistics,

supply chain management, advanced planning, quality,

standardized global systems, and supply chain solutions and

business analytics. When supply chain disruption occurred, Jabil

re-routed supply from alternative sources, allocated limited

production to key customers and distributors, specify and quality

alternative parts, and called on existing suppliers to help reduce

the impact of the disruptions.

8
2.4 Company Mission and Vision

2.3.1. Mission

Jabil Circuits mission is to achieve customer satisfaction through

excellence in design, supply chain management, manufacturing

and repair solutions.

2.3.2. Vision

Jabil vision is to develop and nurture long term, mutually beneficial

customer partnership by delivering the best total manufacturing

services solutions available.

2.5 Company Goal

Jabils goal is to become the world's leading provider of manufacturing

services to enable employees to offer innovative solutions and strategic

benefits to customers proactively. Values of Empowerment and

accountability, customer intimacy, and drive continuous improvement of

our models, and use these values to minimize bureaucracy and

speed up manufacturing in the daily management of our business. We

believe that everyone can make a difference and want to encourage

creativity, innovation, and problem solving aggressive you are as an

individual and as a member of the Groups flagship. Jabil is a vibrant

neighborhood full of people who are motivated to work tirelessly to serve

customers.

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2.6 JABIL organization chart

2.6.1 JABIL Penang organization chart

Figure 2.6.1 Jabil Penang organization chart

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2.6.2 Manufacturing Engineering(ME) organization chart

Figure 2.6.2 Manufacturing Engineering organization chart

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2.7 JABIL Policies

2.7.1 Quality Policy

Jabil goal is to provide valued solutions that meet or exceed

customer expectations. This is achieved through empowered

employees, passionate leadership, and innovative capabilities.

Jabil is fully committed to comply with all applicable quality and

regulatory requirements. Jabil strive to deliver perfect products,

maintain tireless drive for improvement and apply lean principles

while managing the risks. This is to ensure competitive costs,

quality products and timely delivery performance for customers.

2.7.2 5S policy

Jabil practice 5S program in daily activities. This is to maintaining

an organized workplace to eliminate waste.

i. Sort - Sort and identify the items that you actually need and

find appropriate locations for them based on frequency of

use, dimension and weight.

ii. Set In Order Arrange all necessary work items according

to the workflow and make them easy to locate (label) and

use. This can be implementing by draw a current-state map

that shows where all the necessary equipment and tools

are currently located.

iii. Shine Remove all forms of contamination such as dirt,

dust, fluids and other debris. By identify targets on safety

(unsafe condition such as spills on the floor) waste

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 (wasteful conditions such as reaching for tools) and

cleanliness.

iv. Standardize Develop systems and procedures to

maintain and monitor the first 3S by incorporating them into

everyday work activities.

v. Sustain Develop discipline to continue the application,

understanding and improvement of the 5S systems and

procedures.

Sort
Clear the way

Sustain
Set in order
Use regular
Put things in
audits to stay
order
disciplined
Eliminate Waste

Standardize
Shine
Establish
Clean it up
standards

Figure 2.7.2 Summary of 5S process flow

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2.8 Rules and regulations

2.8.1 Employees identification badge

Each employee will be given a badge identification containing

photograph identification purposes. This logo should always be

used in Jabil Circuit. It should be left to the uniformed security or

other employees if asked for the purpose of inspection. Report the

loss immediately to the identification badges and badge of the

Securities Part, replacement will be provided but with a fee of

RM10.00. Badges may be the property of Jabil Circuit and must

be returned to the Human Resources Department when

termination.

2.8.2 Awareness of Electrostatic Discharge (ESD)

Electrostatic discharge (ESD) unexpectedly transferred of

electricity from one object to another. It remains can damage

components or functions of the PCB. This help Jabil Circuit to

reduce the impact of profit sharing as much scrap or rework needs

to be done. ESD brings extensive damage to the PCB it only takes

about 2000 volts of static charges before a person can feel it.

However, the components can be damaged or destroyed by at

least 10Volt. Therefore, the ESD standard ANSI Jabil is based on

ESDS20.20.

Employee or anyone entering the production area or production

line ESD footwear and clothing should be worn daily, over the

entrance, and has to make direct examination before entering

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production. Rules only in the house only approved ESD footwear

to be worn outside the home or factory are not allowed. While

smoke must in full zip and no folding arm allowed.

Figure 2.8.1 Do and Dont on ESD smock

Figure 2.8.2 Do and Dont on ESD shoes

15
Figure 2.8.3 ESD scanning door

Figure 2.8.4 Scanning ESD

16
 CHAPTER 3

SUMMARY OF TASK

3.1 Introduction

This chapter contain summary about the assignment of work and

activities that I had done during the training period at Jabil Circuit. All

the activities start from 14 November 2016 to 14 April 2017. I

summarize all the activities on a weekly basic according to date for 20

weeks as below:

3.2 Summary of weekly activities

3.2.1 Week one (14/11/2016 18/11/2016)

i. Orientation in Jabil Circuit.

ii. Reported to Manufacturing Engineering (ME)

department.

iii. Survey and observe at the production line to learn

how the process of SMT machine.

iv. Learn how to do the daily task (OEE Vms) from the

senior interns.

v. Learn how to do the weekly task (update LEAN blue

wall).

3.2.2 Week two (21/11/2016 25/11/2016)

i. Learn how to check the SMT machine using CAMX

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 ii. Learn how to do damage report which is one of the

weekly tasks in Tuesday.

iii. Enroll and attend the safety courses online.

iv. Attend the A3 and DMAIC class.

v. Learn the weekly task which is checking the cycle

time on build plan.

3.2.3 Week three ( 28/11/2016 2/12/2016)

i. Learn Monday weekly task which is update OEE by

bay by week.

ii. Learn the Tuesday weekly task which is update FNI

damage report.

iii. Learn the Wednesday weekly task that is update the

blue wall in managers room.

iv. Learn how to reporting the priority line of bay daily to

engineer.

v. Memorize the position and location of the machine

(top side and bottom side).

3.2.4 Week four ( 5/12/2016 9/12/2016)

i. Update the OEE by bay by week file and send to

engineer after updated.

ii. Weekly meeting of all interns in ME department with

the supervisor.

iii. Learn how to update FPY report on every

Wednesday.

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 iv. Learn how to upload the feeder setup for production

line.

v. Go through the stencil library package.

3.2.5 Week five ( 13/12/2016 16/12/2016)

i. Teach the new intern on doing the OEE Vms (Virtual

memory system) daily.

ii. Stencil fabrication house visit.

iii. Observation report on stencil fabrication house visit.

iv. Learn the new task for every Friday which is

configuring the watchdog VA parameter.

3.2.6 Week six ( 19/12/2016 23/12/2016)

i. Report the priority line to engineer.

ii. Weekly meeting with supervisor to discuss how to

separate the interns into 3 groups to support PM

(Preventive Maintenance).

iii. Update the FPY report to engineer.

iv. Check the machine time with CAMX.

v. Check the cycle time on the build plan.

3.2.7 Week seven ( 27/12/2016 30/12/2016)

i. Update the daily task OEE Vms.

ii. Learn how to use MES (Manufacturing Execution

System).

iii. Learn how to assign a new route to an assembly

number in MES.

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 iv. Learn how to upload the CSV file that contain the

details of machine into MES.

3.2.8 Week eight ( 3/1/2017 6/1/2017)

i. Learn to validate FSS (Feeder Setup Sheet) and

MES BOM (Bill of Materials) in MES.

ii. Learn how to copy and share the FSS (Feeder

Setup Sheet) in MES.

iii. Learn how to use MES reporting software.

iv. Learn how to do a comparator check.

3.2.9 Week nine ( 9/1/2017 13/1/2017)

i. Learn how to create deviation program for some

assembly number.

ii. Learn how to apply deviation program after created

it.

iii. Go to production line and follow the senior shift

programmer to learn the process of production.

iv. Learn the orientation of component in order to

setting in program.

v. Learn how to load the program into XPF machine.

3.2.10 Week ten ( 16/1/2017 20/1/2017)

i. Support the technician at production line in doing PM

(Preventive Maintenance).

ii. Weekly meeting with supervisor and presenting the

package based on what had learned in this

internship.

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 iii. Learn how to update the back end program in MES.

iv. Support the programmer in updating the back end

program in MES.

v. Upload the feeder count.

3.2.11 Week eleven ( 23/1/2017 26/1/2017)

i. Upload feeder count.

ii. Learn the process of NPI (New Product Introduction)

in production line.

iii. Learn how to change feeder size or pitch in Fuji

Flexa software.

iv. Preventive maintenance on production line.

3.2.12 Week twelve ( 2/2/2017 3/2/2017)

i. Discuss the topic of DMAIC project with group

members.

ii. Upload feeder count.

iii. Find the A3 problem solving ideas to present in

weekly meeting.

3.2.13 Week thirteen ( 6/2/2017 10/2/2017)

i. Sad Weekly meeting with supervisor to present the

brief idea and name of DMAIC project.

ii. Upload feeder Count.

iii. Meeting with supervisor to discuss the further

position in this internship to learn more knowledge.

3.2.14 Week fourteen( 13/2/2017 17/2/2017)

i. Preventive maintenance

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 ii. Weekly meeting to present the A3 problem solving

report to supervisor and others intern.

iii. Learn how to buy off orientation incoming.

iv. Learn the purpose of teach part.

v. Update back end program.

3.2.15 Week fifteen ( 20/2/107 24/2/2017)

i. Update the back end program.

ii. Weekly meeting with supervisor and for other

interns to presenting their own A3 problem solving

report.

iii. Learn how to change to nozzle head in FujiFlexa

program.

iv. Learn how to remove the old version program from

current program storage to another files in FujiFlexa

software.

3.2.16 Week sixteen ( 27/2/2017 3/3/2017)

i. Preventive maintenance

ii. Weekly meeting to presenting Define of DMAIC

project.

iii. Learn how to help operators to change the

squeegee in MES.

iv. Buy off incoming part orientation.

3.2.17 Week seventeen ( 6/3/2017 10/3/2017)

i. Learn how to support programmer in changing the

stencil part in MES.

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 ii. Weekly meeting with supervisor and watch other

interns to present their own Define of DMAIC

project.

iii. Lecturer visit.

iv. Learn how to reset the tray offset z to value 0.

3.2.18 Week eighteen ( 13/3/2017 16/3/2017)

i. Reset tray pick offset Z value.

ii. Change nozzle head program.

iii. Updating backend program.

3.2.19 Week nineteen (20/3/2017 24/3/2017)

i. Learn how to recognize the vision types needed to

use on SMT machine.

ii. Weekly meeting to present M of DMAIC project to

supervisor and other interns.

iii. Learn how to update feeder setup sheet based on

build plan.

3.2.20 Week twenty (27/3/2017 31/3/2017)

i. Update Feeder Setup Sheet based on build plan.

ii. Weekly meeting with supervisor to present the A of

DMAIC project.

3.2.21 Week twenty one (3/4/2017 7/4/2017)

i. Update feeder setup based on build plan.

ii. Update backend program

iii. Weekly meeting with supervisor to represent the

Measure and Analyze of DMAIC project.

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3.2.22 Week twenty two (10/4/2017 14/4/2017)

i. Update backend program

ii. Weekly meeting to presenting Improve of DMAIC

project.

24
 CHAPTER 4

TECHNICAL REPORT

4.1 Introduction

This chapter consists of interns tasks and activities through internship

completion about 22 weeks assigned. As industrial trainee under ME

(Manufacturing Engineering), Intern has been assigned and exposed to

various task and manufacturing environment.

4.2 Preventive Maintenance

Preventive maintenance is a simple method to ensure that you get

reliable and efficient performance from plant and equipment within

organization. It is important to ensure that machinery does not break

down and causing downtime. This simple maintenance program will help

to achieve that. The preventive maintenance is planned monthly for

every bay on production line. In this preventive maintenance, the

machine will be clean and check by technician. In order to do the

preventive maintenance fast, there are VA (Visual Aid) and checklist to

help on the technician to complete the preventive maintenance. The

current interns under ME (Manufacturing Engineering) are separate into

3 groups which is group A, B and C. These 3 groups will support

technician in preventive maintenance by turns. The preventive

maintenance is planned for 12 hours to ensure that the preventive

maintenance will be completed.

25
4.2.1 Steps Taken To Do Preventive Maintenance On Nozzle

Step 1: Press the emergency button on Pick and Place machine and

pull the Pick and Place machine.

Figure 4.2.1.1The red button (emergency) on machine.

Step 2: Take the nozzle station out of the Pick and Place machine.

Figure 4.2.1.2 Nozzle station.

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Step 3: Take out the nozzle from nozzle station.

Figure 4.2.1.3 Example nozzle.

Step 4: put the nozzle onto the nozzle holder setup.

Figure 4.2.1.4 Nozzle put on the nozzle holder setup.

27
Step 5: Insert the nozzle holder setup into the automatic nozzle

cleaning machine.

Figure 4.2.1.5 Nozzle holder setup insert into cleaning machine.

Step 6: Set timer to 2 minute for washing and 2 minute blowing.

Figure 4.2.1.6 LCD shows the time of wash and blow

28
Step 7: Pull out the nozzle nest and put it under the camera to verify

the condition of nozzle.

Figure 4.2.1.7 Nozzle put under camera for inspection

Step 8: If the nozzle still in bad condition, then nozzle need to clean

manually using IPA and air gun blower. Then, check again with

camera.

Figure 4.2.1.8 Nozzle in good condition and clean

29
 Figure 4.2.1.9 Nozzle not yet clean

Step 9: Use the beam coat and apply the IPA on it. Then use beam

coat to clean the nozzle manually.

Figure 4.2.1.10 IPA

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 Figure 4.2.1.11 beam coat

Step 10: Use air gun blower to blow the nozzle after clean nozzle

using beam coat and IPA.

Figure 4.2.1.12 Air gun blower

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Step 11: After checked, put all cleaned nozzle into nozzle station

based on machine configuration.

Figure 4.1.13 machine nozzle configuration.

Step 12: Insert nozzle station back into Pick and Place machine.

Figure 4.1.14 Nozzle put back on machine.

32
4.3 Introduction to Overall Equipment Effectiveness (OEE)

OEE (Overall Equipment Effectiveness) is the gold standard for

measuring manufacturing productivity. Simply put it identifies the

percentage of manufacturing time that is truly productive. An OEE score

of 100% means you are manufacturing only Good Parts, as fast as

possible, with no Stop Time. In the language of OEE that means 100%

Quality (only Good Parts), 100% Performance (as fast as possible), and

100% Availability (no Stop Time). Measuring OEE is a manufacturing

best practice. By measuring OEE and the underlying losses, you will gain

important insights on how to systematically improve your manufacturing

process. OEE is the single best metric for identifying losses,

benchmarking progress, and improving the productivity of manufacturing

equipment (i.e., eliminating waste).

Figure 4.3 shows Availability times Performance times Quality equals to

OEE.

4.3.1 Availability

Availability takes into account all events that stop planned production

long enough where it makes sense to track a reason for being down

(typically several minutes).Availability is calculated as the ratio of

Run Time to Planned Production Time:

Availability = Run Time / Planned Production Time

33
 Run Time is simply Planned Production Time less Stop Time, where

Stop Time is defined as all-time where the manufacturing process

was intended to be running but was not due to Unplanned Stops.

Unplanned Stop The manufacturing process is scheduled for

production and is not running because of an event like an Equipment

Failure or Material Shortage. Unplanned Stops affect OEE

Availability. Breakdowns or Planned Stops (example: Changeovers).

Run Time = Planned Production Time Stop Time

4.3.2 Performance

Performance takes into account anything that causes the

manufacturing process to run at less than the maximum possible

speed when it is running (including both Slow Cycles and Small

Stops).Performance is the ratio of Net Run Time to Run Time. It is

calculated as:

Performance = (Ideal Cycle Time Total Count) / Run Time

Ideal Cycle Time is the fastest cycle time that your process can

achieve in optimal circumstances. Therefore, when it is multiplied by

Total Count the result is Net Run Time (the fastest possible time to

manufacture the parts).

Since rate is the reciprocal of time, Performance can also be

calculated as:

Performance = (Total Count / Run Time) / Ideal Run Rate

Performance should never be greater than 100%. If it is, that usually

indicates that Ideal Cycle Time is set incorrectly (it is too high).

34
4.3.3 Quality

Quality takes into account manufactured parts that do not meet

quality standards, including parts that need rework. Remember, OEE

Quality is similar to First Pass Yield, in that it defines Good Parts as

parts that successfully pass through the manufacturing process the

first time without needing any rework. Quality is calculated as:

Quality = Good Count / Total Count

This is the same as taking the ratio of Fully Productive Time (only

Good Parts manufactured as fast as possible with no Stop Time) to

Net Run Time (all parts manufactured as fast as possible with no

stop time).

4.3.4 Steps Taken To Do A OEE VMS (Virtual Memory System) Report

OEE VMS is use for fill in downtime which is the data output take

from the Performance Report. Performance Report is a report that

operators will fill in after one of model run at one bay.

Step 1: Go to penrdcappweb04/penweb/Default and open OEE VMS

on APPLICATIONS.

Figure 4.3.1 Jabil website

35
Step 2: Log in to the page

Figure 4.3.2 login page

Step 3: Select CAMX from input column

Figure 4.3.3 shows column input

36
Step 4: select the bay and make sure the OWT and CAMX is same

Figure 4.3.4 shows the data is same

Step 5: Select the MES route and MES step.

Figure 4.3.5 shows the MES route and MES step

Step 6: Allocate the downtime on the system based on the excel files

Figure 4.3.6 shows the downtime selection on the left

37
 Figure 4.3.7 shows the excel file that record downtime

Step7: After allocated all downtime, save the report and the report will

automatic updated.

Figure 4.3.8 shows the data updated

38
4.4 Introduction to Surface Mount Technology (SMT)

Surface Mount Technology (SMT) is a method for constructing electronic

circuits in which the components (SMC) Surface Mounted Components

installed directly on the surface of printed circuit boards (PCB). Electronic

devices so made are called Surface Mount Device (SMD). In the industry

it has largely replaced the technology construction method via through-

hole components. SMT is a modern form of process technology for the

manufacture of components and assembly of PCB assemblies.

Electronic components are directly placed and attached to the surface of

the PCB.

4.4.1 List of machine in Surface Mount Technology (SMT) process

i. Multifunctional Printing Machine (MPM)

ii. Koh Young

iii. Gluing machine

iv. NXT machine

v. XPF machine

vi. Reflow oven

vii. Automated Optical Inspection machine (AOI)

viii. Router

ix. Manual insert

x. Fluxer machine

xi. Wave soldering machine

xii. Press fit

xiii. 5DX (X-Ray)

39
4.4.2 Surface Mount Technology (SMT) process flow

Figure 4.4.1 Flow of SMT process

40
4.4.3 Function of Multifunctional Printing Machine (MPM)

The function of MPM is to print the solder paste on Printed Circuit

Board (PCB) by pressuring squeegee on stencil. The equipment

used in MPM machine is:

i. Circuit board that ready to be print solder on it to connect a

part to another.

ii. Stencil to allow for direct placement of solder paste to the

surface to be soldered. .

iii. Solder paste used to be apply on the PCB board and is

only to the areas where the solder is required.

iv. Squeegee is the important tools that used to push and

press the solder paste through the stencil in order to print

the solder on the area. The squeegee has different speed,

angle and pressure that are important for the quality of

solder printed.

v. Benchmark is software on the computer that used to

operate and control the Multifunctional Printing Machine

(MPM).

vi. Support Block and Support Pin are tools that made of iron

and used to support the PCB from falling.

41
Figure 4.4.2 Multifunctional Printing Machine (MPM)

Figure 4.4.3 Squeegee

42
 Figure 4.4.4 Stencil

Figure 4.4.5 Support Pin

43
4.4.4 Koh Young machine

Koh Young also called as solder paste inspection as a machine that

check the solder paste after the MPM had printed the solder paste

on PCB. The solder paste must be checked before going to pick and

place machine to prevent the failure of the PCB. There are many

defects occur in stencil printing process. The defects of solder paste

can be detected through this machine is:

i. Missing solder paste

ii. Solder paste excess

iii. Solder paste miss place on PCB

iv. Shape of solder paste

v. Total amount of solder paste

vi. Bridging

Figure 4.4.6 Koh Young machine

44
4.4.5 Gluing machine

The gluing machine is a machine that sweeps the glue at certain

place in order to prevent component from falling down when

changing position of part on PCB. This machine will be program as

the total quantity used and right position for PCB. Gluing machine

will only be only on critical areas on PCB. Only a few of PCBs will be

used on this machine. This process will be done when there are big

components on PCB to prevent the component from falling in next

process.

Figure 4.4.7 Gluing machine

45
4.4.6 Pick and Place machine

The pick and place machine that used on this SMT process is Fuji

NXT machine. The functions of NXT machine are:

i. A flexible machine that can mount multiple type of

component onto PCB.

ii. NXT is one of the most important machine in SMT

process.

iii. Without using any suitable feeder and vision type, the NXT

machine will not pick up and place the component to the

right place.

There are 4 types of nozzle head NXT, the nozzle head used are::

i. H01

ii. H04

iii. H08

iv. H12S

Figure 4.4.8 NXT machine

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 Function of nozzle head is to pick up different size of nozzle. The

nozzle that picked up must be smaller than the size of component in

order to pick up the component and place on PCB.

Figure 4.4.9 shows the pick and place process

4.4.7 Fuji XPF machine

Fuji XPF had several types which are XPF-L, XPF-W and many

more. The machine that I learned is Fuji XPF-L. Machine Fuji XPF-L

is a high speed Multi-Purpose Mounter XPF-L that contains 12 slots

of nozzle. It is a compact machine that offers flexibility and speed to

fulfill the needs of the market. This machine can pick and place big

and small component on PCB. This machine also had 2 parts which

is front and back. On the front, there are 64 slots for feeder and

different size of feeder can be slot. While on the back of the

machine, it is specific for tray that contains chips and processor only.

With these front and back, it is much easier to troubleshoot if there

are error occur in pick and place process.

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 Figure 4.4.10 XPF machine

In addition, the weight of this machine is 1500kg. This machine can

hold 6kg of PCB maximum. In this machine, it has 2 cameras which

is Wide Fiducial Camera that used to check the coordinate of PCB

and Part Camera that can check the pins, polarity and orientation of

components. The advantage of XPF-L is it can place a component in

just 0.144 second/ 25000 cph (chip per hour). Not just that, nozzle

head or other name called x-y robot that is important in SMT process

which the nozzle head will move to complete the pick and place in

SMT process. In XPF-L machine have support pin that used to

support PCB to prevent PCB from rift in mounting process.

Furthermore, the XPF-L machine able to arrange the support pin or

backup pin based on the coordinate X-Y that import from the

program had been set from the programmer.

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Figure 4.4.11 X-Y robot (nozzle head) in XPF machine

Figure 4.4.12 XPF-L feeder pallet

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Figure 4.4.13 Tape and reel component

Figure 4.4.14 Feeder

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4.4.8 Reflow Oven machine

Reflow machine is a machine that used for heating process of solder

paste on PCB. The purpose of this process is to melt solder and

paste on PCB. This step is very important in SMT process in order to

produce a good quality PCB. If PCB occur error like misplace

component, it is hard to repair misplace of component and this

problem causing another loss of PCB. In reflow process, there are

10 heating zone. After heating zone, there is another 1 cooling zone.

After PCB is send to the reflow oven, the reflow oven need to update

the temperature in each zone. The factors that used to determine the

temperature are:

i. Type of solder paste

ii. PCB size

iii. Type of pallet

iv. Quantity of component

Figure 4.4.15 Reflow Oven machine

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4.4.9 Automatic Optical Inspection (AOI) machine

Automatic Optical Inspection (AOI) is an automatic visual inspection of

PCB or LCD and transistor where the camera is automatically scans

and detects component failure. For example, missing component and

quality problem which is the shape of component skewed. It can be

done in several stage through SMT process include bare board

inspection, solder paste inspection, before and after reflow oven and

others stage. The defect and failure that can be detected through AOI

machine are:

i. Area defect

ii. Component unbalance

iii. Missing parts

iv. Component skewed

v. Over solder

vi. Parts folded

vii. Missing solder paste

viii. Bridging

ix. Tombstone

x. Component damaged

xi. Component miss place

xii. Component polarity

xiii. Shorts

xiv. Wave soldering point

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 Figure 4.4.16 Example of AOI machine

4.5 Buyoff incoming part

4.5.1 Check orientation of component

Orientation of component is to show polarity of component or location

of pin 1 for the component. Orientation is important for programmer to

create a program and modify the program. Therefore, learn to check

orientation of component is to prevent program of pick and place

machine occur error. If the orientation in program is wrong, it will

cause wrong polarity when machine picking up part and mount on

PCB. A rework must be done if this problem occur and it causing more

time and cost.

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 Figure 4.5.1 Orientation of component

4.5.2 Check size and pitch of feeder

Before pick and place machine start to mount, the programmer must

make sure the size and pitch of incoming feeder part are well set and

same with the program. The feeder pitch is calculated by the number

of hole between a center of component to another with 4mm each

hole.

Figure 4.5.2 Feeder pitch calculation

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4.6 DMAIC problem solving method

DMAIC problem solving method is an engineering problem solving

method that I had learned in this internship. The DMAIC problem-solving

method can be used to help with any issue that arises, usually by those

who professionals in the organization who have reached green belt level.

The DMAIC problem-solving method that is a roadmap that can be used

for any projects or quality improvements that needs to be made. The

term DMAIC stands for the five main steps in the process: Define,

Measure, Analyze, Improve, and Control.

i. Define

It is important and first step to define the problem or project goals.

The more specific the problem is defined the greater the chance of

obtaining measurements and then successfully completing the

project or solving the problem.

ii. Measure

Measure the problem and defects cause by the problem that

define on the first step. As on measure, the result should be came

out with the defects causing by the problem.

iii. Analyze

Once the measuring stage has defined the addition

measurements, the data is then collected and analyzed. At this

point, it is possible to determine whether the problem is valid or

whether it is a random event that does not have a specific cause

that can be corrected. The data that has been collected can be

used as a base level to compare against measurements after the

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 project has been completed to ascertain the success of the

project.

iv. Improve

After measurements have been taken and analyzed, then possible

solutions can be developed. Test data can be created and studies

launched to find which of the solutions can get the best

improvements to the issue when compared against the original

measurements taken.

v. Control

After the implementation of the solution or project there requires a

number of controls to be put in place so that measurements can

be taken to confirm that the solution is still valid and to prevent

recurrence. The control measurements can be scheduled for

specific date example for monthly, daily, and yearly

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 CHAPTER 5

CONCLUSION

During 5 months industrial training in Jabil Circuit Sdn Bhd, students can gain a

wide knowledge and experience as a student that will soon step into the

working world. The environment and challenges among this training helps

students grow and learned so much.

During the training period, students can applied all the knowledge and skills that

got and learned from my Polytechnics PTSS to do some works in Jabil Circuit

Sdn Bhd. Not only students can gained much more experience on

Manufacturing Engineering (ME) department but also communication skills

among all others working partner. Communication is important because 70% of

work mistake is cause by poor communication.

In addition, students can also learn how to be independent, maintain self-

discipline, patience, mutual assistance, capable of acting alone trust and

courage to face the problem of the work entrusted to them. Students must be

willing to accept any critical event of an error and attempted to turn the error.

Indirectly, these items are very useful for students to use in the present and the

future.

My supervisor Mr.PJ Loh from Manufacturing Engineering (ME) department had

given many learning opportunity for interns. He will meet all of interns that under

ME department to get in touch with us and know about us in task given and

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problem faced. Through the weekly meeting, students can learned the

presentation skills in presenting our package to supervisor. As the sentences

that our supervisor said Comfort zone is a beautiful place, but nothing ever

grow there. Therefore, our supervisor pushes us out of the comfort zone to the

learning zone in order to let us grow. Not just that, our supervisor also provide

us to assign the safety online courses to learn about how to prevent accident

and how important is safety in manufacturing. The interns also had the

opportunity to have an A3 and DMAIC problem solving class in order to let us

learn how to solve a problem using engineering method. Lastly, interns also had

to opportunity to have a stencil fabrication house visit to learn about how the

stencil is made from design to create it into physical stencil.

As a conclusion, the industry training is good and suitable for students to

engage in a real working environment and allows students to gain as much

experience as possible will be used in future. Finally, would like to once again

thank the company Jabil Circuit primarily to supervisors and HR (human

resources) to have received polytechnic students to have industrial training.

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 CHAPTER 6

COMMENTS AND SUGGESTIONS

6.1 Comments

Undergo industrial training about 5 months Jabil Circuit Sdn Bhd.

Below are my comments about the factory:

i. Comfortable environment for work - During the period that

internship at Jabil, most the task that given to us was carry out

with an air-conditioned.

ii. Interns website - Jabil has provided a website for the intern

student. The website consists of rules and regulations, the time

of weekly meeting, the previous interns works for references

and guideline for new interns. All interns can share the jobs

that have done by each other through the website. So the intern

can learn the skill from the website and carry out all the jobs by

refer to the website. It is a very useful guideline and a good

communicate place for the intern.

iii. All engineers, technicians and operators are very friendly and

easy to communicate.

iv. Provided all the ESD equipment & facilities.

v. Good learning place and many opportunities to learn from the

engineers and technicians.

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6.2 Suggestions

6.2.1 Suggestions to students

i. Do a properly preparation on the first day intern for register

which like confirm the industrial training location and

prepared all related document.

ii. Prepare a note to write down the steps and tips that

learned for future references.

iii. Dont be shy to ask and learn to communicate with others

when there is something not understands.

iv. Follow the rules of the industrial.

6.2.2 Suggestions to polytechnic

i. Polytechnic should be always get-in touch with industrial

company in order to know the situation and activities of

students in training.

ii. Polytechnic should prepare a guideline about scope of

industrial training to let the company learn the scope and

plan the suitable training job to the trainee to achieve the

objective of this industrial training.

iii. Arrangement of lecturer visit has to be more details and the

date of lecturer visit should be inform earlier in order to let

the students and the industrial training company to be

prepared for the lecturer visit.

6.2.3 Suggestions to industrial training company

i. Teach the trainee with the ways to do the task and purpose

of doing the task in order to let the trainee clear about what

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 are they doing and why they are doing. In addition, this will

let trainee to learn faster and clear about the work that they

doing.

ii. Provide working task schedule for trainee among the

industrial training.

iii. Provide more opportunity to others intern to learn more

than a job range.

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