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TABLE OF CONTENTS CHAPTER 1 INTRODUCTION 1.0 INTRODUCTION............................................................................................................1 1.1 HISTORY OF SHARP CORPORATION.........................................................................1 1.2 HISTORY OF SHARP .....................................................................................................2 1.3 HISTORY OF S&O ELECTRONIC (M) SDN BHD........................................................6 1.3.1 S&O ELECTRONICS (M) SDN BHDs ACTIVITIES..............................................7 1.4 POLICY OF SHARP & ONKYO ELECTRONIC (M) SDN BHD ...................................8 1.5 SHARPS BUSINESS PHILOSOPHY AND BUSINEDD CREED..................................9 1.6 SHARPS THINK GREEN POLICY ............................................................................. 10 1.7 SHARP & ONKYO ELECTRONICS FINANCIAL STATEMENT.............................. 10 1.8 S&O ORGANIZATIONAL CHART.............................................................................. 11 1.9 R&D ENGINEERING DEPARTMENT ORGANIZATION CHART ............................ 12 1.9 SHARP & ONKYO ELECTRONICS PRODUCTS ...................................................... 14 CHAPTER 2 LITERATURE REVIEW 2.0 INTRODUCTION.......................................................................................................... 15 2.1 NEW MODEL (PRODUCT) DEVELOPMENT............................................................. 15 Stage 1: Idea generation ................................................................................................... 15 Stage 2: Idea Screening .................................................................................................... 16 Stage 3: Concept Development and Testing...................................................................... 16 Stage 4: Marketing Strategy and Development ................................................................. 16 Stage 5: Business Analysis ............................................................................................... 16 Stage 6: Product Development.......................................................................................... 17 Stage 7: Test Marketing.................................................................................................... 17 Stage 8: Commercialization.............................................................................................. 17 2.2 RESEARCH QUESTION .............................................................................................. 18 2.3 SCOPE........................................................................................................................... 18 2.4 LIMITATION ................................................................................................................ 18 2.5 CONLUSION................................................................................................................. 18 CHAPTER 3 RESEARCH METHODOLOGY 3.0 INTRODUCTION.......................................................................................................... 19 3.1 RESEARCH DESIGN.................................................................................................... 19 3.2 DATA COLLECTION METHOD.................................................................................. 20 1.Primary data .................................................................................................................. 20 2.Secondary data .............................................................................................................. 20 3.3 INTERVIEWS ............................................................................................................... 21 3.4 DATA ANALYSIS ........................................................................................................ 21 3.5 CONCLUSION .............................................................................................................. 21

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CHAPTER 4 DATA ANALIS 4.0 INTRODUCTION.......................................................................................................... 22 4.1 FINDINGS..................................................................................................................... 22 4.1.1 0 JI STAGE (ZERO STAGE)................................................................................ 23 NAFTA............................................................................................................................ 24 EUROPE.......................................................................................................................... 24 OCEANIA ....................................................................................................................... 24 ASEAN............................................................................................................................ 24 NEW SUFFIX.................................................................................................................. 25 4.1.2 OFF-TOOL STAGE .................................................................................................... 27 4.1.2.1 ENVIRONMENT RELATIONS TESTS...........................................................28 4.1.2.2 PRINTING STRENGTH TESTS ......................................................................37 4.1.3 PRE-PRODUCTION................................................................................................... 42 4.1.4 MASS PRODUCTION................................................................................................ 45 4.2 TIME FRAME OF DESIGN PROCESS IN S&O ELECTRONIC SDN BHD ................ 48 4.3 SEVEN STAGES IN NEW DEVELOPMENT PROCESS ............................................. 53 STAGE 1: PRODUCT DEVELOPMENT ........................................................................ 53 STAGE 2: DESIGN INPUT ............................................................................................. 54 STAGE 3: DESIGN OUTPUT ......................................................................................... 55 STAGE 4: PROTOTYPE STAGE.................................................................................... 55 STAGE 5: TOOLING SAMPLE ...................................................................................... 56 STAGE 6: DESIGN VERIFICATION ............................................................................. 57 STAGE 7: PRODUCT APPROVAL & TRIAL RUN....................................................... 57 4.4 CONCLUSION .............................................................................................................. 57 CHAPTER 5 CONCLUSION AND RECOMMENDATION 5.1 CONCLUSION .............................................................................................................. 58 5.2 MY RECOMMENDATIONS TO S&O ELECTRONIC SDN BHD............................... 61 5.3 SWOT ANALISIS ......................................................................................................... 63 STRENGTH..................................................................................................................... 63 WEAKNESS.................................................................................................................... 63 OPPORTUNITY.............................................................................................................. 63 THREAT.......................................................................................................................... 63 CHAPTER 6 REFERENCES................................................................................................................. 64 CHAPTER 7 APPENDIX...................................................................................................................... 65

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LIST OF TABLE

TABLE 1 HISTORY OF SHARP2 TABLE 2 HISTORY OF S&O ELECTRONIC SDN BHD.6 TABLE 3 S&O ACTIVITIES7 TABLE 4 S&O ORGANOZATION CHART11 TABLE 5 WORKING HOURS & REST TIME...13 TABLE 6 LIST OF PRODUCTS.14 TABLE 7 EXPORT STATISTIC BY DESTINATION14 TABLE 8 HIGH TEMPERATURE CONDOTION..28 TABLE 9 DROPPING ORDER31 TABLE 10 SWOT ANALYSIS.62

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LIST OF FIGURE FIGURE 1 - SHARP LOGO1 FIGURE 2 MR.TOKUJI HAYAKAWA1 FIGURE 3 SHARPS THINK GREEN POLICY..10 FIGURE 4 PERCENTAGES OF SHAREHOLDER OF S&O.10 FIGURE 5 NEW DEVELOPMENT PROCESS IN BUSINESS..17 FIGURE 6 NEW DEVELOPMENT PROCESS IN ENGINEERING..18 FIGURE 7 DATA COLLECTION METHOD .20 FIGURE 8 4 STAGES IN NEW MODEL DEVELOPMENT PROCESS22 FIGURE 9 O JI STAGE.23 FIGURE 10 HIGH OR LOW TEMPERATURE CONDITION30 FIGURE 11 NOISE TEST.33 FIGURE 12 VIBRATION TEST33 FIGURE 13 BAR CODE36 FIGURE 14 REMOTE CONTROL SPECIFICATION36 FIGURE 15 STEEL RULER SCRATCH TEST..37 FIGURE 16 WET CLOTH TEST.38 FIGURE 17 METHOD OF RUBBING TEST38 FIGURE 18 RUBBING TEST39 FIGURE 19 METHOD OF NICHIBAN TEST39 FIGURE 20 METHOD OF CROSS CUT TEST40 FIGURE 21 CROSS CUT TEST...40 FIGURE 22 METHOD OF MITSUBISHI PENCIL SCRATCH TEST40 FIGURE 23 FINGER PRINT TEST..41 FIGURE 24 WORKING MANUAL.43 FIGURE 25 WORKING MANUAL.44 FIGURE 26 ELECTRICAL SCREW DRIVER & SPEAKER.44 FIGURE 27 STAGE 153 vii

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FIGURE 28 STAGE 255 FIGURE 29 STAGE 355 FIGURE 30 STAGE 455 FIGURE 31 STAGE 556 FIGURE 32 STAGE 657 FIGURE 33 STAGE 7..57 FIGURE 34 LEFT VIEW58 FIGURE 35 FRONT VIEW...59 FIGURE 36 RIGHT VIEW59

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CHAPTER 1

INTRODUCTION
1.0 INTRODUCTION This chapter illustrates the background of the organization. The discussion will cover the background of the company, product and services, vision and mission. 1.1 HISTORY OF SHARP CORPORATION

Figure 1 - SHARPs Logo

SHARP is a company that is known worldwide. It has a long and successful history. A company that begins with an invention of mechanical pencils, into developing electronic calculators, which later end up inventing electronic appliances such as televisions, radios, washing machines, camcorders, and LCD televisions. The name SHARP was derived from a mechanical pencil, Ever-Sharp Pencil. The mechanical pencil was invented by the late Tokuji Hayakawa, founder of SHARP Corporation. Mr. Tokuji Hayakawa was involved within the business arena when he was 18 years old. Before involving into the creating of electronic products, he was in the metal industry creating belts. Then he switched towards inventing a mechanical pencil. After a horrible earthquake on 1923, he and his fellow workers move to Osaka, Japan to start their new life. Mr. Tokuji Hayakawa held a laboratory called Hayakawa Metal Industrial Laboratory which they conducted studies of creating an audio. Table 1.1 shows a brief history on Sharp Corporation in Japan.

Figure 2 Mr. Tokuji Hayakawa

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1.2 HISTORY OF SHARP

1912 1915 1925

Sharps founder, Tokuji Hayakawa establishes a metal works in Tokyo. Tokuji Hayakawa invents the Ever-Sharp Pencil. Assembly and marketing of crystal radio sets. Radio broadcasting begins in Japan. Production of the first Sharp-Dyne AC-powered vacuum-tube radio sets. Development of a prototype television set. Mass production of television sets to coincide with Japans first television broadcasts. Mass production of colour television sets. Colour television broadcasting begins in Japan. Mass production of microwave ovens. Mass production of solar cells and silicon based photovoltaic cells. Development and mass production of the worlds first all-transistor desktop calculator. Development of electronic desktop calculators incorporating integrated circuits. Marketing of Japans first microwave with turntable Development of ELSI chips. Marketing of electronic calculators incorporating ELSIs. Akira Saeki becomes president. Changes name from Hayakawa Electric Industry Corporation to Sharp Corporation. Gray Establishes Corporate Development Center. Mass production of LSIs. Mass production of liquid crystal displays. Development of the worlds first COS electronic calculator incorporating a liquid crystal display. Development of a thin-filmed EL element. Development of 9 mm-thin electronic calculators and foldable incorporating electronic circuit films. Introduction of solar-powered calculators. 2

1929 1951 1953

1960

1962 1963 1964

1966

1969

1970

1973

1974 1975

1976

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Worlds first mass production of 44-pin CMOS LSIs using a film carrier. Development of ultra thin (7 mm) electronic calculators with CMOS LSIs. 1977 1979 Introduction of 5 mm-thin card-sized, sensor-touch electronic calculators. Development of the dual-cassette tape recorder. Introduction of a word processor with pen-based input. Development of pocket-sized electronic translators. Development and introduction of the worlds first super-thin (1.6 mm) card-sized calculator. 1981 Development of the worlds first long-life laser diode. Introduction of portable VCRs for camera/television recording. 1982 Introduction of pocket computers using BASIC language. Introduction of the worlds first combination personal

computer/television set. 1983 Worlds first mass production of ultra-thin EL displays. Mass production of amorphous solar cells using Roll-to-Roll Method. 1984 Development of a kerosene heater with an order-absorbing system that absorbs odors when lit. Introduction of a one-touch warming microwave oven that cooks by recognizing the type and amount of food using sensor-microcontroller action. 1986 Haruo Tsuji becomes president. Introduction of a combination microwave / toaster oven. Development of a VHD video disc player capable of rendering 30 images. 1987 Development of an electronic organizer with multiple functions. Introduction of liquid crystal display colour televisions with a 92, 160pixel, TFT drive system. Introduction of a DAT unit capable of digital recording and playback. Development of an erasable / rewritable magneto-optical disk.

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1988

Introduction of an A4-size notebook word processor with address / schedule management. Development of the worlds first 14-inch large-screen, thin-profile, and high-definition colour TFT liquid crystal display unit. Introduction of the worlds first dual-swing door refrigerator. Introduction of an English-to-Japanese translation system. Introduction of a cordless phone / answering machine with 100m range. Introduction of 100-inch liquid crystal display video projectors. Development of the worlds first full-colour desktop facsimile. Introduction of a home copier / facsimile. Development and introduction of 8.8-inch wall-mount liquid crystal display colour televisions. Development and introduction of an 8.4-inch colour TFT liquid crystal display for colour notebook computers. Development of a multimedia-compatible 16.5-inch, colour TFT liquid crystal. Development and introduction of a high definition television with simplified MUSE decoder. Development and introduction of the worlds first liquid crystal display View cam. Development and introduction of the worlds lightest MD headphone player. Development and introduction of a fully automatic washing machine with stainless steel water-saving tub. Development and introduction of a dual-swing door refrigerator, using non-CFC vacuum insulation panels. Development and introduction of an all-in-one Personal Information Tool for business use. Development and introduction of News Vision, a wide-screen television which offers viewers easy and ready access to news anytime while watching television. Development and introduction of a colour Japanese word processor. Development of the worlds largest (28-inch) TFT direct-view colour 4

1989

1990

1991

1992

1993

1994

1995

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liquid crystal display unit. Development and introduction of the worlds most compact and lightweight PHS unit. 1996 Introduction of Internet-ready colour liquid crystal display notebook personal computers (PC-A400 series), equipped with vivid clear liquid crystal display screens offering 30% greater brightness. Development and introduction of the Internet-ready Colour Personal Information Tool that can gather, create, and send information, sound and images in colour. 1997 Development of the reflective-type Super-Mobile TFT liquid crystal display, which displays 260,000, colors in amazing clarity even in direct sunlight, and with no backlight. 1998 Katsuhiko Machida becomes president. Introduction of an ultra-thin, ultra-light, B5-file size notebook personal computer with a large 11.3-inch TFT color liquid crystal display. 1999 Development and introduction of a liquid crystal display television with a large 20-inch, high-quality screen that gives users freedom in viewing style. 2000 Introduction of the worlds first 28-inch wide-screen liquid crystal display television compatible with digital hi-vision broadcasts. 2003 Introduction of worlds first 37-inch LCD TV with built-in terrestrial digital-HDTV tuner. Development of industrys first technology for recycling waste plastic (polypropylene and polystyrene) and reusing its material for four products covered by Home Appliances Recycling Law. 2004 Development and introduction of Water Oven that roasts food with superheated steam for delicious, healthy dishes. 2005 Introduction of AQUOS 65-inch LCD TV, the worlds largest full-spec hi-definition, hi-resolution LCD TV. 2006 Opening of SHARP Kameyama Plant No. 2, the worlds largest integrated LCD facility to adopt the 8th generation mother glass substrates.
Table 1 History of sharp

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1.3 HISTORY OF S&O ELECTRONIC (M) SDN BHD In 1974, the construction of the company started. Back then, it was formerly known as Sharp Roxy Corporation (Malaysia) Sdn. Bhd. (SRC). It takes almost a year to complete its construction. In 1976, it was officially launched by Tun Dr. Mahathir Mohammad who was the Vice Prime Minister at that time. Since then, it became the first overseas production and export base for SHARP Corporation. The company then changed its name to Sharp & Onkyo Electronic (Malaysia) Sdn. Bhd. (S&O). For over than 35 years, it carves many successful achievements and will be remaining in the S&O history for future improvement and innovation. For a brief history of S&O, refer to Table 1.3 Company S&O Contents (formerly Name: Sharp & Onkyo Electronics (M) Sdn. Bhd. (Formerly known as Sharp-Roxy Corporation (M) Sdn. Bhd.) State: Established: Business Figure 1.4 S&O Plant History: 1976-Portable radio, mono-radio CTR started 1979-Music centre started 1981-Stereo radio cassette tape recorder started 1982-Car stereo started 1988-Product with CD started 1991-CD optical pick-up started 1993-Facsimile and cordless phone started 1996-CD-ROM optical pickup/mechanism started product with MD start 1998-Received 1st Malaysia Good Design Award for DXV500 1999-Portable MD started Local CD mini-component system design completed 2000-Optical pick-ups started (for portable MD/DVD-ROM use) In 2000 afterwards, the company intends to realize further business expansion pertaining to optical pickups and enrich R&D activities inclusive of product design related to MD Kedah 1974

known as SRC)

Future Deployment:

Table 2 History of Sharp & Onkyo Electronic (M) Sdn.Bhd

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1.3.1 S&O ELECTRONICS (M) SDN BHDs ACTIVITIES

Year 1974 1976 1977 1979 1981 SRC were established.

Activities / Production

Production of portable radio started. Production of mono cassette radio. Music centre started. Auto insert machine were introduced. Production of radio cassette recorder stereo. 2nd factory construction finished.

1982 1984 1985 1986

Production of car audio. ZD (Zero Defect) activities were launched. Chip insert machine were introduced. Self development model were launched. QCC activities were introduced. 2nd factory development were finished. CD (Compact Disc) production was launched. Construction of warehouse was completed. 3rd factory completed. CD pick up was completed. ISO 9002 BSI Certificate was awarded. Production of facsimile. Production of cordless telephone was launched for overseas production. Production of cordless telephone was launched for Japan production. Cordless facsimile for Japan model was launched. ISO 9001 BSI Certificate was awarded. Production of MD (Mini Disc) started.

1987 1988 1989 1990 1991 1992 1993 1995 1996 1997 1998

1999

DVX 500 model was awarded for best design. MD pick up was launched. EMS ISO 14001 BSI Certificate was awarded. Production of portable MD started.

2000

Optical pick up started.

Table 3 - S&O Activities

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1.4 POLICY OF SHARP & ONKYO ELECTRONIC (M) SDN BHD Every company has their own policy including Sharp & Onkyo Electronic Malaysia (S&O). For S&O, they have two (2) policies to be followed by all S&O staffs which are policies on quality and policies on environment. S&O gives the highest priority both on quality and environment as in Figure

POLICIES ON QUALITY To satisfied the customers. To maintain the confidence of S&O to become a producer. To fulfill customers request and requirements. To make sure the products fulfill all the specification and the conditions that had agreed to. To become a leader through high technology innovation. To make sure that all the employees know the companys policy on quality.

POLICIES ON ENVIRONMENT Continue to increase the environment quality and to avoid fire. To set and always check the specific targets, objectives and plans for environmental management. To ensure all S&O staffs aware with the policy by telling the through meetings, posters and policy card that were distributed. To tell the policies to others who are interested through lettering and other methods as in to tell the public when are asked to. To make sure that all the employees know the companys policy on quality.

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1.5 SHARPS BUSINESS PHILOSOPHY AND BUSINEDD CREED

BUSINESS PHILOSOPHY We do not seek merely to expand our business volume. Rather, we are dedicated to the use of our unique, innovative technology to contribute to the culture, benefits and welfare of people throughout the world. It is the intention of our corporation to grow hand-in-hand with our employees, encouraging and aiding them to reach their standard of living. Our future prosperity is directly linked to the prosperity of our customers, dealers and shareholder. Indeed, the entire Sharp family.

BUSINESS CREED Sincerit and Creativity By committing ourselves to these ideals, we can derive genuine satisfaction from our work, while making a meaningful contribution to society. Sincerity is a virtue fundamental to humanity - Always be sincere. Harmony brings strength - Trust each other and work together. Politeness is a merit Always be courteous and respectful.

Creativity promotes progress Remain constantly aware of the need to innovate and improve. Courage is the basis of a rewarding life Accepts every challenge with a positive attitude.

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1.6 SHARPS THINK GREEN POLICY

Figure 3 - SHARPs Think Green Policy

1.7 SHARP & ONKYO ELECTRONICS FINANCIAL STATEMENT

Figure 4 Percentages of shareholders of S & O Electronics

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The companys paid up capital is RM 24,000,000 which is about U$ 6,600,000. S&O invest a lot of money for their company. Sharp was able to achieve a significant improvement in both sales and profits during the first half compared to the same period last year. For the six months ended December 31 2010, net sales were 2329,401 billion yen, up 15.1% from the same period last year. Operating income was 66,510 billion yen. Net income was 21827 billion yen, an improvement of 30418 billion yen from the net loss of 8591 billion yen in the same period last year. There are four (4) shareholders of the company which are SHARP Corporation, ONKYO Corporation, Terengganu Incorporation and late R. Hanim Hussein. Figure 1.16 shows the percentages of the shareholders. Refer to Table 1.5 for the list of the board of directors.

1.8 S&O ORGANIZATIONAL CHART Managing Director Mr. Hiroshi Ogawa

Director / Senior General Manager of Mr. Asami Administration Director / Senior General Manager of Mr. Keiji Shibasaki Production / Production Engineering (P.E.) Director Director Director Director Director Director Director Mr. Noboru Fujimoto Mr. Nobuaki Okuda Mr. Toyoki Suzuki Mr. Kazuya Terazawa Mr. Mohammed Rhiza Bin Dato Ghazi Dato Dr. Abdul Latiff Bin Awang Mr. Wan Osman Bin Wan Long
Table 4 - S&O Organizational Chart

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1.9 R&D ENGINEERING DEPARTMENT ORGANIZATION CHART

SENIOR GENERAL MANAGER

GENERAL MANAGER

SENIOR MANAGER (MECHANICAL) CONSULTANT MANAGER

SENIOR MANAGER (ELECTRICAL) MANAGER

ASSISTANT MANAGER

ASSISTANT MANAGER

SENIOR ENGINEER

SENIOR ENGINEER

ENGINEER

ENGINEER

ASSISTANT ENGINEER

ASSISTANT ENGINEER

TECHNICIAN

TECHNICIAN

CLERK

CLERK

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To make sure the company can run properly, they must hire employees to fill each of the department. There are a total of 1, 581 people at the end of September of 2010. From the sum, it can be divided into three departments which are production department, nonproduction department and engineering departments. For the production department, there are a total of 204 men and 845 women. A total of 364 men and 168 women are in the nonproduction department. As for the engineering department, there are 116 men and 33 women. The above figures are exclusive to the 17 members from the SHARP Corporation from Japan and temporary staffs.

From the total of the employees, the percentage for the men are higher which are 66.4% (1, 049 people) while for women consists of 33.6% (532 people). Percentage of employees according to races, the Malays is the highest which are 54.9% (868 people), followed by the Indians which are 31.6% (500 people), 12.7% (201 people) for the Chinese and lastly 0.8% (12 people) for other races.

Proper time for the employees to rest is important in this company as less time to rest can cause tiredness though too much time can cause time loss and production loss. Start Lunch / Tea Time Monday Thursday Friday Finish Mond Friday ay Thurs day 1st Factory 07:55 (Onkyo) 2nd Factory ( sharp) Office 07:55 AM AM 10:00 AM 10:10AM 12:00 PM 12:40 PM 03:00 PM 03:10 PM 07:55 AM 10:15 AM 10:25AM 12:30 PM 01:10 PM 03:15 PM 03:25 PM 10:30 AM 10:40AM 12:30 PM 01:10 PM 03:30 PM 03:40 PM 10:00 AM 10:10AM 01:10 PM - 02:20 PM 03:30 PM 03:40 PM 10:15 AM 10:25AM 01:10 PM - 02:20 PM 03:45 PM 03:55 PM 10:30 AM 10:40AM 01:10 PM - 02:20 PM 04:00 PM 04:10 PM 05:30 PM 05:35 PM 05:30 PM 05:35 PM 05:30 PM 05:35 PM

Table 5 Working Hours and Rest Time

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1.9 SHARP & ONKYO ELECTRONICS PRODUCTS S&0 production produces many types of products. For easy reference, the products are divided into two which are finished goods and the other is key component.

Category Finished Goods

Products CD / DVD Mini / Micro Compo AV Receiver MD / DVD Compo System Home Theater System Aquos Theater / Rack System Sound Bar I-Pod docking Related products

Key Components

MD / CD Optical pick-up / mechanism MD unit MD / CD changer unit PWB unit (BD / LCD Module related, etc)

Local R&D Category

CD / DVD Mini / Micro Compo MD component system I-Pod docking Related products Home Theater System Rack System
Table 6 - List of S&O products.

2005 USA, Canada Europe Japan Asean Malaysia Others Total 21% 33% 16% 8% 9% 13% 100%

2006 14% 56% 11% 5% 5% 9% 100%

2007 10% 62% 9% 3% 8% 8% 100%

2008 7% 61% 8% 3% 11% 10% 100%

Table 7 Export Statistic by Destination (Amount Base) in Percentage

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CHAPTER 2 LITERATURE REVIEW

2.0 INTRODUCTION The research that I am planning to do is about new model development process in R&D department. This research takes place in S&O Electronics (Malaysia) Sdn.Bhd. This research is mainly about the new model development processes that have been used in new model to manufacture in S&O Electronic (Malaysia). 2.1 NEW MODEL (PRODUCT) DEVELOPMENT

In business and engineering, new product development (NPD) is the term used to describe the complete process of bringing a new product or service to market. There are two parallel paths involved in the NPD process: one involves the idea generation, product design and detail engineering; the other involves market research and marketing analysis. Companies typically see new product development as the first stage in generating and commercializing new products within the overall strategic process of product life cycle management used to maintain or grow their market share.

The process of NPD is crucial within an organization. Products go through the stages of their lifecycle and will eventually have to be replaced. There are eight stages of new product development. These stages will be discussed briefly below: Stage 1: Idea generation New product ideas have to come from somewhere. Some sources are including as mention below: Brainstorming thinking about it within the company employees Creating a new product based on some observed need Competitors. Customer , supplier Thinking of a new product based on some accident or chance circumstance

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Stage 2: Idea Screening This process involves shifting through the ideas generated above and selecting ones which are feasible and workable to develop. Pursing non feasible ideas can clearly be costly for the company. The screeners should ask several questions: Will the customer in the target market benefit from the product? What is the size and growth forecasts of the market segment/target market? What is the current or expected competitive pressure for the product idea? What are the industry sales and market trends the product idea is based on? Is it technically feasible to manufacture the product? Will the product be profitable when manufactured and delivered to the customer at the target price? Stage 3: Concept Development and Testing The organization may have come across what they believe to be a feasible idea. Here the in charge development should develop the marketing and engineering details such as: Investigate intellectual property issues and search patent data bases Who is the target market and who is the decision maker in the purchasing process? What product features must the product incorporate? What benefits will the product provide? How will consumers react to the product? How will the product be produced most cost effectively? Prove feasibility through virtual computer aided rendering, and rapid prototyping What will it cost to produce it? At last the testing the concept by asking sample of prospective customers about what they think of the idea usually via choice modeling Stage 4: Marketing Strategy and Development A proposed marketing strategy will be written laying out the marketing mix strategy of the product, the segmentation, targeting and positioning strategy sales and profits that are expected. Stage 5: Business Analysis The company has a great idea, the marketing strategy seems feasible, but will the product be financially worthwhile in the long run? The business analysis stage looks more deeply into the

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cash flow the product could generate, what the cost will be, how much market shares the product may achieve and the expected life of the product. Stage 6: Product Development Finally it is at this stage that a prototype is finally produced. The prototype will clearly run through all the desired tests, and be presented to the target audience to see if changes need to be made. Stage 7: Test Marketing Test marketing means testing the product within a specific area. The product will be launched within a particular region so the marketing mix strategy can be monitored and if needed, be modified before national launch. Stage 8: Commercialization If the test marketing stage has been successful then the product will go for national launch. There are certain factors that need to be taken into consideration before a product is launched nationally. These are timing, how the product will be launched, where the product will be launched, will there be a national roll out or will it be region by region. "make enough to sell" manufacture a large amount to send out to the stores that will stock the items so enough inventory on hand for the public to buy launch "promotion campaign" Below diagrams show the flow of new product development process for a business and engineering field:

Figure 5 - New development process for business

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Figure 6 - New development process for engineering

2.2 RESEARCH QUESTION My research based on Research & development department. The research question of this study is in the follows: How S&O develop a new Model (product) begins from idea generate until mass production. The name of process to create a new model. 2.3 SCOPE The research focused on the new product development in Research & Development department .This study focuses on the flow of process or steps in new model development that S&O implement to invent a new product. 2.4 LIMITATION There were several problems that have been faced during in order to collect the data. My most of research took part in research and development department of S&O only. Information I gathered just from mechanical engineering and electrical engineering only. 2.5 CONLUSION As a conclusion, this chapter describes about literature review about my topic. A walk in interview has been conduct with my supervisors to collect the data about new product development process. Besides that, some other sources also have been used such as journals, articles, and books are also have been used to collect more relevant details and informations about the studies. 18

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CHAPTER 3
RESEARCH METHODOLOGY 3.0 INTRODUCTION This chapter underlines the research methodology. This chapter is organized into five sections. It begins by discussing about research design to be used in this study. Next the chapter will present data collection method by explaining how the data was selected, data collected and data analyzed. Then this chapter discusses about interviews. Then, this chapter discuss about data analysis and finally about limitations for this study. Research methodology is more than a collection of methods used to perform a research but there is a systematic investigation to solve problem. The research methods refer to the methods and techniques used by the researchers in performing the research. This chapter will give an overview of the methodology phases that were used in this study. This stage is important in do this report which one of the fulfillment in this project. Topper (1994) say, methodology means the study of methods. For this study, it has been followed a descriptive nature where the information collected from various sources. In this case, researcher has conducted a redundant to gain knowledge regarding to the new product development in S&O Electronic Sdn. Bhd. The analysis is done by interview, reference in library with the support of journal, books, magazines, newspaper articles, and internet resources. 3.1 RESEARCH DESIGN In explaining what a case is, Yin (1989) suggests that the term refers to an event, an entity, an individual or even a unit of analysis. It is an empirical inquiry that investigates a contemporary phenomenon within its real life context using multiple sources of evidence. Anderson (1993) sees case studies as being concerned with how and why things happen, allowing the investigation of contextual realities and the differences between what was planned and what actually occurred. According to Yin (1984) there are three types of case study research exploratory, descriptive, and explanatory. In my research I subscribed to exploratory case study because this research can be useful for example to study process in companies. This case study 19

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methodology involves use of multiple sources of data. This might involves the use of multiple respondents within the organization or multiple data collection. 3.2 DATA COLLECTION METHOD

Figure 7 - Data Collection Method

Figure shows the methods that are used to collect the information about the new product development in S&O Electronic Sdn. Bhd. Qualitative method has been used in this project. Qualitative data may give a depth of understanding in terms of the inner workings of human organization. There were two types of data sources that have been used to obtain the necessary input for further analysis of the study. These two types of data sources: 1. Primary data The primary data are which are being collected by the researcher for the specific purpose of answering the problem on hand. It is taken by the observation during the research and interview with the person who concern for this new product development area in S&O Electronic Sdn. Bhd. Observation that I mention here is not only by seeing the process but myself doing the assembly process. It helps me more to understand about the assembly process. 2. Secondary data The secondary data being obtained by the literature review, journals, books and article from internet. The analyses have been done according to the scope of this project. The 20

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informations have been gathered by interview and analysis. Besides that, books and journals are also been used to find the information according to the research. 3.3 INTERVIEWS The goal of any interview is therefore to see the research topic from the perspective of the interviewee and to understand how and why he or she comes to have this particular perspective. Interviews were conducted with open-ended questions for this study to allow interviewee to expand upon particular points or make general comments about the research topic. 3.4 DATA ANALYSIS The findings are presented in the qualitative approach. The analysis is done according to the scope of this project. The qualitative data obtained from the interviews, build a picture of the journey that has been followed in S&O Electronic Sdn. Bhd with different initiatives in order to identify the information about new product development. 3.5 CONCLUSION As a conclusion, this chapter describes the methodology that has been taken during the research. An interview has been conduct with S&O Electronic Sdn. Bhd to collect the data about the new product development. Besides that, some other sources also have been used such as journals, articles, and books are also have been used to collect more relevant details and informations about the studies.

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CHAPTER 4
DATA ANALIS 4.0 INTRODUCTION In this chapter show the findings from S&O Electronic (M) Sdn Bhd. The information gathered is based on interview and guide from Chief Engineer, Mr. Faizatul Hazli and engineer, Mr. Shahrizul Anuar from R&D department of the S&O Electronic Sdn.bhd, archival records and information from the Were Sharp magazine and other documents from S&O Electronic Sdn.Bhd.

4.1 FINDINGS From information I gathered for research titled new product development process in S&O Electronic Sdn. Bhd based on interview from my chief engineer, Mr.Faizatul hazli and engineer, Mr.Shahrizul Anuar, these are the findings for my research. Here S&O Electronic dont use 8 steps to create a new model moreover S&O Electronic just use four steps in developing new model developing in S&O Electronic Sdn Bhd. The frame of steps is shown below:

O JI STAGE

OFF TOOL

PRE- PRODUCTION

MASS PRODUCTION

Figure 8 4 stages in new model development

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4.1.1 0 JI STAGE (ZERO STAGE)

MARKET SURVEY

NEW PRODUCT PLANNING OUTLINE

FROM PLAN

PRODUCT

COST STUDY

TOTAL

PLAN

QUANTITY

DEPARTMENT

DEVELOPMENT SCHEDULE

LIASE WITH CUSTOMER ON ANY CLARIFICATION

ISSUE DRAWING
Figure 9 O Ji Stage

The first stage in S&O Electronic (M) Sdn Bhd is 0 Ji stage formely known as Idea generation, idea screening and concept development for other company. Idea generation and idea screening stage will be done in SEM Company where located in Shah Alam. Before the idea generation, SEM will conduct market survey for the new model. A market survey is an important requirement for initiating any successful product or service. The objective of a market survey is to collect information on various aspects from different aspects. A market survey is a systematic collection, recording, analysis and interpretation of data relating to the existing or potential market for a product or services. A market survey is a useful tool for contact with the market. The systematic and intelligent use

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of this tool can reduce risks of decision making under conditions of uncertainty. Through a market survey we can obtain information in the following areas: Size of market. Pattern of demand. Buying habits and motives. Past and present trends for this product. The next step after market survey is planning outline for new product. Production planning department will conduct this step. The new product planning will concern about destination for the new product. The meaning for destination in S&O Electronic (M) Sdn Bhd is different countries to distribute this new product. It is because the design and material are different for each destination. Some of examples of destinations are: NAFTA U.S.A Canada Mexico EUROPE Europe (Germany base) Northern Europe U.K OCEANIA Australia New Zealand ASEAN Malaysia Philippines Thailand Indonesia Singapore Hong Kong Taiwan Korea East Europe Russia Central & south America Brazil Argentina

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NEW SUFFIX Asia India Jordan Reunion Egypt Syria Saudi Arabia Kuwait, Bahrain Turkey

Some different will be made for each destination. These changes will make by request from buyer from each destination. Some of example of changes is: Voltage. Voltage selector. Safety regulation (radiation). Frequency range. Operation manual. Saving energy. Plug adaptor. Serial number list. Bar code. Type of AC cord. SEM engineer will start do draft outer drawing and send to S&O Electronic Sdn. Bhd. The outer drawing just consist the shape of new product and dimension. Product planning department from S&O Electronic (M) Sdn. Bhd will conduct their analysis about design drawing. Then they will start doing general product plan. General product plan will consist about information of model name, colour information and block copy and schedule for development process. General product plan will be different for each destination. After that, R&D department will take over their part in development process. After product planning stage complete, design concept stage will start. Design concept will start with construction study. The manager will start to do rough cost estimation for the new model. Besides that, the engineer also prepare budget for new mould and tooling. This is called mould budget application. The concern engineer will do new part list for the new model. Normally this task will be done by one engineer to prevent any confuses among parts. The engineer will start doing 2D and 3D drawing. Power Draw software is used for 2D drawing and Pro Engineer or Solid Edge software is used for 3D software.

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Layouts study will begin once the drawing is complete. Layout study will consist about paper box cabinet designing. Firstly, engineer will make prototype using paper box. Its called paper box cabinet designing. Paper box prototype used to see the shape of new model. Firstly, the engineer roughly will assemble it. Rough assembly will concern about power transformer position, battery arrangement,

sw headphone jack position, interface each major

parts and PWB layout. The engineer will check space factor. Base on this study engineer will review the cost estimation for that particular new model which had been done during the planning stage. From paper box designing engineer will get to know about the problem of assembly and other problem too. After the paper box design, the engineer will start to do assembly drawing or its called part drawing. Engineer will issue part quotation for handmade sample. ABS natural (one kind of plastic) is used for made handmade. Handmade is used to check the assembly process, wire arrangement, PWB position and more in complete and close shape to the actual product. While in assembly time the engineer will identify all major and minor problems. So the engineer should think a way to solve all kind of problems appear while handmade assembly such as adjust wire arrangement or PWB size, construction, strength, usability, production capability and so on. 0 Ji evaluation meeting will be held to confirm the new model. Quality control and Production Engineering departments engineers will join 0 Ji evaluation meeting. After complete all kind checking using handmade, the engineer will start to prepare off- tool insertion drawing. Mould meeting will be held and engineer will discuss about mould making. After meeting the engineer will update and issue official drawing for mould construction. Normally tooling process for major plastic parts will be held in China. Chief engineer who charged for new model will fly to china for tooling confirmation and buy-off process. The chief engineer will explain about drawing to the supplier for the molding process.

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4.1.2 OFF-TOOL STAGE After 0 Ji stage was completed, off tool stage starts. In this stage more set will produce for study purpose. If problem occurred while study times such as assembly problem or new set not function well and more, the engineer should find solution for these kinds of problems. They should upgrade and improve that new model towards the actual mass production. For reconfirm the new model reliability test will be done. These tests are important in order to ensure the quality of the product and meet consumers satisfaction. Evaluation and troubleshooting will be widely performed in this stage by the engineers of group in charge. For the model that been request by OEM such as Denon or Onkyo the sample of the set together with the test results will sent to the buyer. The engineer should decrease the problem appear while study time before the pre-production stage. Some crucial test and the briefing are as follows as the the determination of a good product can be produced. Before the test is done, new model meeting will be held to all the engineers concern to the model. Where after meeting there are several works will be done at a time packaging team will take on responsibility on manuscript, instruction manuscript, s/m manuscript. Electrical engineer in the same group will be sending PWB drawing to off-tool stage and send for either pre-prod or PWB mould drawing- where electrical department will issue for making H/M PWB for off-tool sample. They will secure PWB and new parts for SRC off-tool. Engineers in electrical department will start moving on parts collection and prepare to next level that is to insertion drawing. PWB model will be sent to Production Engineer department. At the same time both electrical and mechanical improvement will be done continuously while the meeting for off-tool is done. In the off-tool meeting issues about problems occurred and counter measure will be discussed thoroughly. Stage after off-tool is tooling sample (Design Evaluation& Review), where safety application will be checked. For example to Sweden SEMKO, ETL SEMKO (formerly Edison Testing Laboratory) is a division of Intertek Group plc (LSE: ITRK) specializing in electrical product safety testing, EMC testing, and benchmark performance testing. ETL SEMKO operates more than 30 offices and laboratories on six continents. SEMKO (Svenska Elektriska Materiel "The Swedish Electric Equipment Control Office") was until 1990 the

body responsible for testing and certifying electric appliances in Sweden. The "S" mark was mandatory for products sold in Sweden until the common European CE mark was adopted prior to Sweden's accession to the European Union. Countries that are listed in the tooling 27

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sample and design evaluation is Russia (GOST), TISI (Thailand), DENAN (Japan), KETI (KOREA), CNS (Taiwan), and SIRIM (Malaysia). Safety sample will be sent over to these countries to check their level of safety, engineering department will be waiting for safety or EMC approval. Stage right after tooling sample (design Stage right after tooling sample (design verification evaluation and review) is the stage where final cost decision will be made. Final decision will be bring as a discussion to confirmation meeting. In the confirmation meeting engineers will most discuss about problems solved, and a must that every problem that occurred should be solved. The crucial thing in this meeting is all parts must have been approved and before the meeting engineers should be positive about sound quality where quality committee sounds must be checked. Below is some listing of tests that S&O Electronic Sdn Bhd is done for new model as strength tests. These tests are done to confirm product quality and product stability. Furthermore these kinds of tests normally test product function and appearance. 4.1.2.1 ENVIRONMENT RELATIONS TESTS 1. Compression test

The compression test in high temperature storage use to check whether the products or packaging containers are deformed with the lapse of time and how they are deformed with the elapse of time. Normally, products deformed due to static compressive load given when goods are stacked during extended warehouse storage. The test shall be conducted by the following conditions.

High Temperature Storage Temperature Time All knobs Weight 65C Over 30 Hours Packing condition which is written in packing working manual Weight shall be applied on top of carton with metal plate or hard plate And total stacking layer
Table 8 - High Temperature conditions

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Remark: weight applied on top of the carton must be even.

Formula: W= unit weight = stacking height D= sotacking layer, h = carton height Example: H = 3000mm; h= 350 mm D = H/h = 3000/350 = 8.6 D = 8 layers D 1 (minus 1 layer) = 7 W = total weight applied on top compression The compression test carried out at PQA department where the chamber located. The chamber use to store product at specify temperature that set by the engineer or assistant engineer. The engineer stored audio set with packing around 30 hours with the temperature 65C with weight load been put on top of the packaging unit according to the specifications. Date and time should be written and sticked outside of the chamber used, right after load the audio set. The purpose of sticking the notice paper with time, date and name is crucial to prevent from others to use the same chamber or vice versa. After the test, the engineer will checks for problems for operation appearance, construction and mechanism after the products return to room temperature. By default, the engineer had to check problem after the products cooled down. Normally, the checking start after one hour the compression test finished. But most of the time, we checked the products problem after 15 minutes it is taken from the chamber. 2. High or Low Temperature Test High or Low aging test is a test that simulates the set in a country that have extreme temperature. The purpose is to see the durability of the set when it is in the extreme temperature condition. There are two (2) types of temperature test which are the high temperature and the low temperature. The temperature is set according to the destination of 29

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the set such Japan, the temperature is set for the low is -10C and the high temperature is 65C. Firstly the set is put under the low temperature while aging. Once complete low temperature test, the set is check. Engineer will check function and new model condition. The same procedure going for the high temperature test, the set will be put under aging and then will be check for errors. Examples of problem occur are floating labels and unable to open the CD tray due to the gear is frozen. This manual is usually applied for storage test in high and low temperature which is conducted by design review for new model which is developed by audio equipment division. The purpose of this test is to check unit reliability during transportation and warehousing. The test will be conducted in by following condition below:

Figure 10 high or low temperature condition

Usually if it is impossible to take this test with packed condition, can just carry out this test without packing material. However, this test with packed condition shall be conducted on one of stage (off tool pre- prod, and mass production).Any defectives or problems occurred on its appearance, construction and etc. Before checking further, sets will be left in normal temperature before any further checking is done. All the defectives from the test shall be reported to department concern by specified form. The counter measure shall be reported and get from responsible department. The counter measure shall be discussed and confirmed by off tool investigation meeting or confirmation meeting and etc. The test result will be reported by fill in confirmation result and condition by specified after test. 3. Drop Test Drop test is used to determine the container's ability to retain and protect its contents after a free fall. It duplicates the rigors associated with manual or mechanical handling at loading and unloading points. The engineer performs repeatable tests on flat, corner, and edge drops. All drops are without rotation to your test package so it lands in the same orientation in 30

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which it was released. Using accelerometers and computer-aided testing software, the engineer can measure the acceleration levels experienced anywhere on the package. This technology allows us to determine if product cushioning is required or not.

Drop test is conducted by design review for new model which is developed by audio equipment division. The purpose of this test is to check unit reliability and strength due to any impact during transportation. This test will be conducted by the person in charge in any specific model and a person from packaging whom will take data during the test. This test by individual carton shall be conducted by the following conditions. Drop test by the several cartons will be conducted, if there are several cartons and necessary to take drop test. The standard corner shall be most weak point to compare with other corner. Drop test shall be conducted by the following order.

Order 1 2 3 4 5 6 7 8 9 10

Dropping place Standard corner Short length edge which is linked with standard corner Middle length edge which is linked with standard corner Long length edge which is linked with standard corner Most small face which has standard corner Opposite face of 5 Middle face which has standard corner Opposite face of 7 Most big face which has standard corner Opposite face of 9
Table 9 - Drop Tests dropping order

Remark: If there is moving parts in the units. The dropping order can be changed which has most impact for moving parts. 4. G-value test Products are distributed to users through various physical distribution routes. While the products are being transported or loaded or unloaded, they are subject to receive impacts. Therefore the product and product package should be properly designed so as to endure these impacts. The importance to determine the product strength is to determine the weak or sensitive parts or portions within the product. And to provide necessary information for 31

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package design (optimum cost vs performance).G factor or product fragility is an important criterion relating to product strength and package design. G factor definition- maximum deceleration a product can handle before damage occurs. Higher G factor indicates higher fragility. There are two types of G-Value determination test: Internal G To determine inside of G Value the unit at stable area and at the unstable area. Example of the stable area inside the unit is like the metal chassis where power transformer is fixing on. Example for unstable area inside the unit usually is around CD changer area or MD unit area where the construction is very weak and severe. The complete packing set will be drop on its bottom surface and the G value will be read by the G sensor meter. Surface G To determine the G value for every surface of the unit by dropping the complete packing set on every surface of the packing case. The drop sequence should follow the sequence for normal drop test where the drop corner must be the weakest corner compare to the others. G= a/g Where, a = acceleration (m/s 2 ), g = gravitational acceleration = 9.81 m/s 2 Force is generated when a standstill object is moved or a moving object is stopped. From Newtons 2nd Law: Force = Mass x Acceleration F = ma (1) Weight = Mass x Gravitational Acceleration W = mg .... (2) m = W/g From (1) F = ma = (W/g) x a = W x (a/g) Where a/g = G, therefore F = WG (3) 5. Noise test Noise test in S&O is a crucial test to do, test procedures to check several kind of noise which may occur during operation. The main purpose of this test is to prevent market claims due to any abnormal noise during operating set.

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Figure 11 Noise Test

Noise meter must be in front of side as (A) which has 5cm distance. Noise meter must be located near power transformer as (b) which has 5cm in distance. The unit will be operate by 50/ 60 HZ of power line frequency when check the noise level. But for mechanism group our scope and judgment will be more towards power transformer: below 28dB by 50/60Hz of power line frequency. Mechanism group will note humming noise for transformer, and determine the influence by dispersion during production for transformer. Mechanism group will also determine noise in play condition target should be below 35dB and if there is continuous noise is considered NG (No Good). Actually several models which has 40 Db noise level also can be found in the market. Therefore, relative checking with this models can be conducted when take judgment; in this case, periodically noise will be taken note as (NG). Mechanism also targeted noise operation below 60dB in start and finish operation, continuous noise id below 55dB is the target. Checking items will be CD/DVD function; where mechanism group will check on normal playback each mode that is playback, pause, fast cue up/down, record & playback. In case the audio model has line out (cant take in a single model) so, full set will be put in together for instance with speakers and amplifier.FM/ AM Function are checked to confirm tuner frequency so that auto scan stop frequently due to interference by noise where this items will be checked in measurement labs. Record playback will be checked by frequency modulation On/Off condition, where this item will be checked b frequency signal generator. Furthermore, tape function will be checked in 4 different criterions. Normal playback each mode such as Playback, FF, REW, Dubbing and etc will be checked by mechanism group. This unit will be operating by 50/ 60 HZ of power line frequency in noise level. Incase if there are noise and buzzing sound occurred during the test, it will be confirmed by listening. Same checking will be done for Aux/ game input, scart, S-video & Video out function. Where 33

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all this item will be checked will full connection according to actual connection as illustrated recommended in operating manual. 6. Screw Torque Test Torque test done to test screw holes torque durability especially for plastics screw hole. The torque test is to test the screw holes torque durability (for plastics screw boss, for metal burring hole). Second purpose is to check the screw hole is not loose after 10 cycles, where every single torque is tested differently. Thirdly is to confirm the life time of the screw hole when apply the minimum torque and maximum torque. This test used electric screw driver, digital torque meter, test piece (sample parts), screw applied on the hole (part code). Test method is by setting up the torque meter value for electric. Screw driver using digital torque meter. Use electric screw driver to tighten the screw in different torque value. And tighten the screw bolt become loose where for every screw test new screw is crucial. Every screw holes must withstand the max torque apply at least by 10 times without loose. If the screw holes become loose before 10 times screw applied, the result will consider as NG. It will need to review back the whole dimension compare to the design drawing using pin gauge and also review the mechanical construction at the screwing. The minimum and maximum screw torque can be applied on the screw hole is different for plastics and metal parts. The torques applies for metal parts basically higher than the plastic parts. The minimum and the maximum tolerance for torque apply is different depends also on the screw type applied. 7. Vibration test Vibration testing is accomplished by introducing a forcing function into a structure, usually with some type of shaker. Alternately, a DUT (device under test) is attached to the "table" of a shaker. For relatively low frequency forcing, servo hydraulic (electro hydraulic) shakers are used. For higher frequencies, electrodynamics shakers are used. Generally, one or more "input" or "control" points located on the DUT-side of a fixture are kept at a specified acceleration. Other "response" points experience maximum vibration level (resonance) or minimum vibration level (anti-resonance). Two typical types of vibration tests performed are random- and sine test. All sharp products and packaging are designed to assure their quality against normal vibration and resonance that may occur during distribution before receipts by customers. The 34

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scope of this vibration test is to standardize prescribes the vibration test to be conducted with packaged goods, manufactured and delivered by sharp, as well as procured finished products. However, this does not apply to OEM products manufactured according to buyers specification and etc. in addition, products installed in automobiles such as LCD TVs and MD players shall be tested as indicated in each group standard. Purpose of the test is to check whether vibration for packaged goods is established and implemented to protect products from vibration and resonance during transportation and distribution. Besides that, testing equipment- the vibration tester consists of a vibrating diagram and a vibrator and shall satisfy the conditions below: Vibration can be tested in both vertical and horizontal directions. A sinusoidal waveform is preferable for vibration. Testing at the maximum acceleration of more than 9.8 m/s2 (1G) is possible. The vibration frequency should be continuously and logarithmically variable between 5 and 50 Hz and fixed constantly at9.8 m/s2. Continuous automatic sweeping is possible and sweep time can be adjusted. The vibrating diagram should be light in weight, sufficiently strong and equipped with metal fittings that can clamp or firmly secure a sample in place. Furthermore, any defectives (problems) occurred during the test will be reported to department concern by specified form. The countermeasure shall be reported and get from responsible department or it will be discussed and confirmed in meeting. And finally test report will be kept in shipment approval meeting document.

Figure 12 Vibration Test

8. Bar Code Test This test is done to check printing condition for bar code label which is applied or printed on the packing case and prevent problem such as fail to read bar code label by bar

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code reader in the market. Bar code can be checked after cutting bar code print on the packaging case, selected sample will be checked by bar code scanner. There are few steps to set bar code label, and to take standby mode and put bar code reader. Then, fix bar code location that standard line of bar code can be located in center on two lines of bar code label centerline as picture below

Figure 13 Bar Code

Figures on bar code will be in 10 keys or numbers. If there are 12 digits, 0(zero) will be added in front of the figures to make the bar code as 13 digits. 9. Remote control test All of remote control on the products which is developed by audio group will be covered by this procedure. The purpose of this test is to prevent design problem related to the remote control sensing in the open field. Same batteries will be used for different remote controls. Complete set will be placed on measurement table. Remote control will be put apart from the unit. The distance from new model to remote which has no effective will be plotted on attached sheet. As for the top side, confirm the distance and angle from 5- 45 , and from 1 meter distance to 13 meter.

Figure 14 Remote control tests specification

S&O has their own specification to operate the distance that the unit can be operated an over z6 meter distance for front, left and right side. As for the top view distance must be 5 within 5 meter range. But there is no specified specification for bottom side (as considered no user should use the remote control to operate any model from bottom surface). This item will be judge to compare with other competitors models and current models. There are some 36

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procedures to check malfunction: the shortest range to check malfunction by remote from zero to 100 cm in slow condition. Any noise from out-side: inverter fluorescent (sharp ls-m 127 lynx) will be installed as drawing; remote control will be located as in checklist and will be operated to check, to check any malfunction at any distance. When problem is occurred, the detailed of problem will be informed to engineering department. The counter measure for the problem will be made by engineering department. 4.1.2.2 PRINTING STRENGTH TESTS So many tests are done for printing strength test in off tool stage to make sure the printing in good condition. Examples of printing strength tests are shown below: 1. Steel ruler scratch test Purpose - To confirm that the scratched surface dont have any abnormal condition occur. Method scratch the painted surface or silk surface with steel ruler. Check point paint come out condition should not in zig zag condition.

Before Test 2. Migration test -

Figure 15- steel ruler scratch test

After Test

Purpose to make sure no change of colour for the paint using after test. Method apply few drops of ethyl alcohol and metyl alcohol on test surface. Let the solvent dry and clean the surface by using dry clean cloth.

Check point the paint on the tested surface should not be change of colour.

3.

Wet cloth test Purpose to confirm that the paint on tested surface is not coming off after test. Method place a wet cloth on surface for 30 minutes then remove the wet cloth and let it dry naturally. After dry, perform Nichiban tape test on the surface. Check point- the paint on the tested surface should not be take off after apply Nichiban tape test. 37

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Before Test 4. Sunshine test -

Figure 16 Wet cloth test

After Test

Purpose to confirm that the painted surface is not changing colour after test. Method cover up the half of test piece and place the test piece at sunshade area for 48hrs.(Do not direct expose to sun light)

Check points the painted surface is no changing colour after test.

5. High temperature pressure Purpose to confirm that the painted surface is not appearing polyethylene foam mark after high temperature load. Method place the test piece in chamber and put the polyethylene foam piece on the top of test piece and apply loaf 80g/cm. 65 temperatures will set for 48 hours. Check point tested surface should be free from polyethylene foam mark.

6. Rubbing test The purpose of this test is to confirm painted surface in specification. The test method is applying cloth and rubs the test surface for a stroke distance of 30mm, load 500g/cm. A different stroke is applied for different paint.

Usually for normal paint, 50 strokes are applied. For PU paint.200 strokes are applied and for parts always expose to hand, 2000 strokes applied. The picture below shows the test method for rubbing test:

Figure 17 Method of rubbing test

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Check point - Surface must not see base material colour after test. The engineer must check the tested surface and make sure the paint is not take off or breaking after rubbing test. In the report engineer must insert photo of rubbing surface before and after test.

The same method is applied for wet rubbing test formally known as alcohol rubbing test but must apply alcohol drops in rubbing cloth before the test. The same strokes are applied for rubbing. The judgment will be same as dry rubbing test. After test make sure no paint is came out from surface.

Before Test 7. Nichiban Tape test -

Figure 18 Rubbing Test

After Test

Purpose of Nichiban Tape test is to make sure the painted surface not come out after tape test. This test is primarily used to determine sufficient curing, good adhesion and bonding between the ink and the painted surface. Commonly used tape is Nichiban or Nitto tape to be applied over the printed surface. Ensure no bubble trap in the tape, press out the air trapped if any. The picture below shows the method for Nichiban tape test.

Figure 19 Method of Nichiban Tape Test

Method At 90 deg angle, give a quick pull and see any printed wording remove and stick to the tape.

Check point - If some trace of ink detected on the tape, it means fail and must check the surface also. Make sure no paint is come out after test. 39

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8. Cross cut test Propose to make sure the painted surface not breaking and come out after test Method cut 1mm interval on test surface area 1cm as shown below:

Figure 20 Method of Cross Cut

Apply Nichiban Tape on cutted surface and holding one of the end of tape and pull it at one stroke as picture below:

Before Test

Figure 21 cross cut test

After Test

9. Mitsubishi pencil Scratch Test Propose To confirm that the scratched surface dont have any abnormal condition occur. Method tilting the unsharpened pencil lead (Mitsubishi Uni H) at 45. Move the pencil 100mm on the painted surface under maximum. Pressure without breaking the lead, then remove the lead waste with erasing rubber as shown below:

Figure 22 Method of Mitsubishi Pencil Scratch test

Check point lead trace should not remain on the painted surface ace or free from pencil mark.

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Remark in case of operation area by customer shall use H grade. Other area which customer doesnt touch shall use F.

10. Finger print test Purpose to confirm that the fingerprint on the painted surface able to be completely wipe off without leaving any mark on the tested area after high temperature storage. Method apply fingerprint mark on the surface of test piece and put it into high temperature as 60 for 48 hours. Wipe the tested surface using dry clean cloth. Check point tested surface must dont have fingerprint mark appear on the surface after test.

Finger Print before 60

After 48 hours in 60
Figure 23 Finger print test

After wipe using dry cloth

These kinds of tests not only done in silk screen only but the engineer will do for every part. For the model HTSL-50, the engineer did this test for: Bottom cover Top cab Back plate Punching grill Front cover Front cover subwoofer Main chassis Pop label , barcode

During these tests, engineer will discuss about off tool problems occurred among these test and engineer should find a better solution for the problem. For an example, if paint came out after rubbing test that means the paint not so good or didnt meet the S&O Electronic Sdn 41

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Bhds quality specification. So the engineer should ask supplier to upgrade the paint specification. Every change in off tool will go through all tests again for quality and safety purpose before mass production start. Every change in material and product will be upgrade very fast during off tool stage. Every new part will name as off tool part 1, off tool 2 and so on. It is because to differentiate the different from beginning until end. Every part must submit for approval from manager before. The engineer should submit the parts for approval with ROHS (Restriction of Hazardous Substances Directive) document, approval sticker, drawing, SPC (Statistical Process Control) data from supplier and S&O Electronic Sdn Bhd and supplier data about material. Before Pre-production stage so many approval must get from manager and general manager such as sound quality approval, production approval and so on. Sound quality approval must be approved by sound quality committee members. They will let engineer know if find any difficulties while testing period. In this case engineer who in charge for speaker will find solution for sound quality. If dont have any problem while testing period, the new model can get approval upon tested. Off tool drawing meeting will be held to discuss about off tool problems and counter measure. In this meeting the engineer will let manager know about the problems. At the same time they have to mention about electrical improvement and mechanical improvement. Tooling modification will take part if got any changes in part. Final assembly drawing will be issued for tooling modification process for pre-production stage. Last but not least confirmation meeting will be held to confirm all problems had been solve and all parts approved. For those unapproved part must provide schedule for parts not yet approved. Confirmation meeting is last steps in off tool stage. 4.1.3 PRE-PRODUCTION Preproduction process will be done after off- Tool stage is complete. Before pre production stage, production approval is must. Jig and PWB mould will completed for preproduction stage. A jig is a type of tool used to control the location and or motion of another tool. A jig's primary purpose is to provide repeatability, accuracy, and interchangeability in the manufacturing of products. A jig is often confused with a fixture; a fixture holds the work in a fixed location. A device that does both functions (holding the work and guiding a tool) is called a jig. 42

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PWB It is also referred to as printed wiring board (PWB) or etched wiring board and PCB is a printed circuit board is used to mechanically support and electrically connect electronic components using conductive pathways, tracks or signal traces etched from copper sheets laminated onto a non-conductive substrate. A PCB populated with electronic components is a printed circuit assembly (PCA), also known as a printed circuit board assembly (PCBA). Printed circuit boards are used in virtually all but the simplest commercially-produced electronic devices. This stage is known as product approval and trial run. Where pre-production meeting will be on- call. PCB mould also will be complete during this stage. Other than that, mechanism group will go on with the impedance checker. What is impedance actually? In a simple form the impedance of the load is expressed in ohms, and the relationship between the current and the voltage in the circuit is controlled by the impedances in the circuit. When a signal source, such as our composite video output, sees a very low-impedance circuit, it produces a larger than intended current; when it sees a very high-impedance circuit, it produces a smaller than intended current Pre production sets will be done in small amount about 20 to 30 sets. The purpose of pre- production is to teach the operator about assembly process using working manual and to confirm the new model production capability using actual production process in assembly line. . Working manual is a list of instructions to assembly the new parts. Working manual will compress all instructions include with picture about how to assemble. It will be easy to operator to understand about the process of assembly. It is because sometime the operator are not educated or operator from foreign country. They cannot understand the language in working manual. So the picture in working manual can prevent this problem and can make them easy to understand about assembly process. The working manual will illustrate about the does and doesnt assembly system. For an example doesnt assembly instructions will be like picture shown below:

Figure 24 Working Manual

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The instruction in working manual will be simple language and can understand easily. For an example the instruction to packing the new model will be like as picture shown below:

Figure 25 Working Manual

The 1st step in Pre- production is the officer and line leader who in-charge of the new model will prepare the line with JIG, material in use for the new model and operators. All the parts or components which are supplied by the supplier will be gathered in production line. The engineer will be in production line to supervise the operators. In production line, the assembly process start from automatic insertion, wiring, and final insertion and last with packaging. For every assembly there will be one operator will conduct the operations. For an example the 1st operator will be insert speaker n screw it using electrical screw driver as shown below: Screw

Figure 26 Electrical screw driver & Speaker

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The 2nd operator will insert wire and the process will go until packaging. Every assembly must conduct with careful to prevent reject sets. After complete assemble the new model the sets will be checked by engineer department to ensure all the set are in proper condition. Quality is important before to export to other country. The new sets will be checked according to few specifications which are fixed by S&O Electronic Sdn Bhd. If got any changes or any improvements in parts, rework will be done. Rework means make changes to the entire parts that available for production. For an example rework for electronic parts, the process of removing a component from a printed circuit board and then re- soldering it back on. In a simple way can say like redoing, correcting or rebuilding again in particular parts for better quality. The main purpose in Pre- production stage is to teach the operator about the assembly process. The pre- production stage will end once the operator fully understand and know how to assemble the new model without engineer supervision. Pre production meeting will be held for discuss about pre production problem. If any problems appear they try to correct it before mass production stage. Pre production approval is must to continue mass production. After pre production approval mass production stage will be start. 4.1.4 MASS PRODUCTION After pre production stage complete, mass production will start. Mass production also called as 1st lot stage in S&O Electronic Sdn Bhd. Mass production is the name given to the method of producing goods in large quantities at low cost per unit. But mass production, although allowing lower prices, does not have to mean low-quality production. Instead, massproduced goods are standardized by means of precision-manufactured, interchangeable parts. The mass production process itself is characterized by mechanization to achieve high volume, elaborate organization of materials flow through various stages of manufacturing, careful supervision of quality standards, and minute division of labor. Mass production is capital intensive and energy intensive, as it uses a high proportion of machinery and energy in relation to workers. It is also usually automated to the highest extent possible. With fewer labour costs and a faster rate of production, capital and energy are increased while total expenditure per unit of product is decreased. However, the machinery that is needed to set up a mass production line (such as robots and machine presses) is so expensive that there must be some assurance that the product is to be successful to attain profits. Mass production of assemblies typically uses electric-motor-powered moving tracks 45

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or conveyor belts to move partially complete products to workers, who perform simple repetitive tasks. Based on Wikipedia, Mass production also called flow production, repetitive flow production, series production, or serial production is the production of large amounts of standardized products, including and especially on assembly lines. The concepts of mass production are applied to various kinds of products, from fluids and particulates handled in bulk such as food, fuel, chemicals, and mined minerals to discrete solid parts such as fasteners to assemblies of such parts such as household appliances and automobiles. The term mass production was defined in a 1926 article in the Encyclopedia Britannica supplement that was written based on correspondence with Ford Motor Co. The New York Times used the term in the title of an article that appeared before publication of the Britannica article. It was also referenced by Sir Chiozza Money, the Fabian banker, politician and author, writing in the London Observer in 1919, comparing the efficiency of Mass Production techniques as used in America, with British practice. In S&O Electronic Sdn Bhd, every operator will have each assembly process for the new model as mention in Pre- production stage. Working manual will hang in front of operator to make them remember of the assembly process. Working manual must be correct before they give to production line. A small mistake in working manual or assembly process can make big problem. This problem will bring to rework or redoing again the new product. Rework for a complete new model is complicated. It is because the operators have to open back the carton. The serial number of product must be follow as well like in production like. They have to reassemble the new set to correct the mistake. After correct the mistake, they operator must assemble back the new sets from beginning until end. Rework will take long time because we have to done 2 works in 1 time. Sometimes, manpower for production line not enough to do rework. So the engineers will help operators to do the rework. In S&O Electronic Sdn Bhd, every day each line will have their own target to finish a completed new model sets without any reject or damage. In this stage, the new model is ready for sales. 1st lot which involves around 1000 sets will be proceeds in production line as soon all modification are done to the set in pre production process. However, all the set will undergo a series of test to prevent from any malfunction.

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Overall in this stage only minor problems need to be settled. The minor problem they must settle before export to other country. Officer and line leader will closely supervise operator to prevent any reject sets due to in production line. Supervisor or technicians who charge for the new model will take responsibility for minor problem. They will repair it. If they cannot find solution, officer will bring the new model sets to engineer to ask for the solution. After the 1st lot, the next production will be done with less supervised by

engineering department because next production should be free of problem.

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4.2 TIME FRAME OF DESIGN PROCESS IN S&O ELECTRONIC SDN BHD

Market Research Development Planning and New Product Design Input Concurrent Development Design Concept Design Output Design Evaluation Design Review New Model Meeting Engineering Sample (Off Tool) Stage

Design Review Design Verification Design Verification Sound Quality Confirmation Meeting Product Approval Pre - Production Design Validation Quality Evaluation Mass Production

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1) Market Research v Sharp Corporation (SC) Japan, the customer does the necessary market research to determine suitable product to be develop 2) Development Planning and New Product Meeting v The Product Planning Department does product development planning. v S&O shall participate in the product development meetings with Product Planning Department v Basic lead time : 2 weeks 3) Product Development v R&D team shall: 1. Organize the design team 2. Finalize the product features, estimate product costs 3. Finalize the development schedule 4. Obtain the necessary resources 5. Liaise with the customer on any matter for clarification. v Basic Lead time: 3 weeks 4) Design Input v S&O shall receive the following material from SEM Design Centre & Product Planning Department: 1. Design drawing 2. General product plan 3. Information of model name 4. Colour information 5. Block copy v The R&D team shall prepare the development schedule and the minutes of the Model meeting v Basic lead time : 4 weeks 5) Concurrent development design concept v The R&D team shall coordinate with other departments 1. Organize the design conceptual meeting 2. Propose and develop the design concepts and layouts study 3. Develop the product according to customer requirements 4. Control product cost within target v Basic lead time: 6 weeks

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6) Design output v The R&D team shall: 1. Prepare Combine Drawing for construction and space factor 2. Prepare schematic diagram and new part drawing 3. Design printed wiring board (PWB) 4. Generate the New parts list 5. Prepare the process flow chart , generate the bill of material(BOM) 6. Obtain new non-tooling or typical parts samples and evaluate 7. Develop hand make samples(Prototype) v Basic lead time : 6 weeks 7) Design evaluation v The R&D team shall: 1. Evaluate the hand make - samples as per Design check sheet (electrical and mechanical) or specification / drawings and record the evaluation results 2. Implement improvements identified into the product design into related drawings, specification and documents 3. Prepare the product specification 4. Prepare operation manual manuscript for customer 5. Prepare block copy manuscript for customer v Basic lead time : 2 weeks 8) Design review v The R&D team shall: 1. Organize the design review meeting 2. Review the design and Hand Make samples together with the related departments 3. Determine improvements to be made in relation to product design. 4. Implement the improvements into the design. v Basic lead time:2 weeks 9) New Model meeting v The R&D team shall: 1. Organize the new model meeting with all related departments and functions. 2. Brief on product features, functions and development schedule. 3. Evaluate and consolidate feedback as appropriate into the development stages. v Basic lead time : 1day 50

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10) Engineering sample (Off - Tool) stage v The R&D team shall 1. Issue improved drawings and specification to suppliers to develop and obtain the required parts through Purchasing Department. 2. Collect the required parts, assembly units, construction drawing. 3. Assemble the off tool sets, evaluate and record in the evaluation report. Take product specification data and update customer if required. 4. Prepare sample set for customer evaluation and comments. v Basic lead time: 2 weeks 11) Design review v The R&D team shall: 1. Organize the Off Tool design Review meeting. 2. Review the design and Off Tool sets together with the related department. 3. Determine the improvements to be made in relation to product design. 4. Implement the improvements into the design v Basic lead time : 1 week 12) Design Verification v The R&D team shall: 1. Evaluate the Off Tool sets as per design check sheet (Electrical and Mechanical) or specification/ drawings and record and verify the results. 2. Receive customer comments and study improvements counter measures. 3. Implement improvements identified into the product design and update the related drawings, specification and documents v Basic lead time : 1 week 13) Design verification sound Quality v The R&D team shall: 1. Evaluate the product sound quality and record the result. v Basic lead time : 2 weeks 14) Confirmation meeting v The R&D team shall 1. Organize the confirmation meeting, report to the new parts status 2. Consolidate feedback as appropriate into the pre production v Basic lead time: 1 day 51

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15) Product approval v The R&D team shall : 1. Organize production approval meeting 2. Conduct final review and finalize the product quality and production processes 3. Obtain product approval from managing director. v Basic lead time: 2 days 16) Pre production v The R&D team shall: 1. Liaise with the production and other support department to organize the production lines and stations 2. Determine the quality to run for pre- production trials. 3. Monitor production processes are done in a controlled manner according to prevailing production, quality control and procedures 4. Prepare service manual manuscript for customer v Basic lead time : 1 week 17) Design validation Quality Evaluation v The R&D team shall: 1. Monitor the products are according to requirements and record pre prod check sheet. 2. Receive the quality assurance department test and evaluation report when available as input for mass production improvement. 3. Follow up and participate through the pre prod meeting. v Basic lead time: 2 weeks 18) Mass production( 1st lot) v The R&D team shall: 1. Liaise with the production and other support departments to continue monitor the product quality and design for further improvement. v Basic lead time : 1 week

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4.3 SEVEN STAGES IN NEW DEVELOPMENT PROCESS I assigned in mechanical engineer group. This information I gathered from new development flow chart that general manager gave to me when I was in practicum. This flow chart gives us a lot of information about seven stages in doing new model. These seven stages include in 4 steps of new development process. A briefly briefing about the stage is shown below: This 1st stage, 2nd stage, 3rd stage and 4th stage is about O Ji stage where the idea of invention begins. The processes are show below: STAGE 1: PRODUCT DEVELOPMENT

MARKET SURVEY

NEW PRODUCT PLANNING OUTLINE

ISSUE DRAWING
Figure 27 Stage 1

Study new product feature plan require by customer in term of new layout, appearance, new device or technology Study and comments the design sketch base on the technical factors as follows. Space for moving parts, fitting for each portion , material thickness Gate point, material flow for tooling construction Finalize the design sketch drawing Design center will issue final drawing Product plan department will give the product planning outline

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DESIGN CONCEPT

LAYOUT STUDY

FINALISE OUTLINE

PLANNING

FINAL DRAWING

Figure 28 Stage 2

Product planning or design center will go through a few steps. There are: Design drawing General product plan Information of model name Colour information Block copy Review again the final design sketch base on final design concept and layout Design concept stage will do about: Construction study Rough cost estimation Mould budget application New part list Layout study consist Paper box cabinet designing Rough assembly Check transformer position Page | 54

INDUSTRIAL TRAINING Battery arrangement Interference of each major parts PWB layout Cost estimation STAGE 3: DESIGN OUTPUT

ROUGH SCHEMATIC DRAWING

O JI PWB

O JI PWB DRAWING

Figure 29 Stage 3

Rough schematic drawing will consist about parts list. Part list is a table which explains about parts or components required to build new model. Engineer will design new parts drawing for off tool sample. The O ji PWB stage will issue for handmade sample. Other name for handmade is prototype. STAGE 4: PROTOTYPE STAGE

O JI SAMPLE

O JI EVALUATION MEETING

Figure 30 Stage 4

Before stage 4, the engineer must issue for mould quotation, issue for handmade sample, mould budget approves and lastly they must fix the mould maker. Operation checking will be held such as

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INDUSTRIAL TRAINING Combining and construction check Fitting and gap check Ventilation hole and safety distance check Electrical PWB layout position check Stage 5 and stage 6 is all about off tool steps. Every step must follow each stage to meet product quality. The process in stage 5 and stage 6 is given below: STAGE 5: TOOLING SAMPLE

NEW MODEL MEETING TRANSFER MATERIAL OFF TOOL

OFF TOOL DRAWING MEETING

MECHANICAL IMPROVEMENT

ELECTRICAL IMPROVEMENT

Figure 31 Stage 5

Issue for making handmade. Secure PWB and new parts for SRC off tool. Parts collection and prepare insertion drawing. Checker point position sent to production engineer department. Lastly, the manager and engineer will discuss off tool problems and countermeasure.

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INDUSTRIAL TRAINING STAGE 6: DESIGN VERIFICATION

SOUND QUALITY APPROVAL FINAL COST CONFIRMATION MEETING DECISION

Figure 32 Stage 6

Study and improvement base on initial customers feedback Conduct reliability test Continue review the design and make improvement on tooling modification for trial run stage The last stage in design team is about product approval and trial run. This stage is about Pre production steps in new development. The process of stage 7 is shown below: STAGE 7: PRODUCT APPROVAL & TRIAL RUN

PRODUCTION APPROVAL

PER - PRODUCTION
Figure 33 Stage 7

Conduct new parts confirmation and product approval meeting Finalize the balance design problem and judgment on product quality to determine if sample produced could justify for trial run stage Assist production on inspection process Pre production meeting and pre production approval to continue mass production. 4.4 CONCLUSION As a conclusion, it shows that S&O engineer seems good with these 4 steps. Engineers are following this step to fulfill S&O product specification. S&O have its own specification to give a good and sustainable product to customer. Page | 57

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CHAPTER 5
CONCLUSION AND RECOMMENDATION 5.1 CONCLUSION

Training in S&O gives a huge impact to the trainees life as they have learned a lot of things. They have learned on time management, proper ways to talk to different level of staffs, knowledge and many more. Practical training is a must for every student as it can boost up the students knowledge, curiosity and communications. As for S&O, their product is in the top quality therefore kept up the good work. After my internship for 6 months in S&O Electronic Sdn Bhd, I got to know a lot of things in research and development (R&D) engineer department. The first of all I got know about how a new product is created from beginning until the product in market. Not easy as I think before. There are a lot of steps and stage must go through to complete a quality and a sustainable product. I assigned to mechanical engineer group. There are 3 persons in 1 group including myself. My group in charge for new model named HTSL50 as shown below:

Figure 34 - Left view

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Figure 35 - Front view

Subwoofer

Sound bar

Figure 36 Right view

This product defined as worlds slimmest sound bar. HT-SL50 is a sound bar home theater system consisting Sound Bar and Subwoofer. My chief engineer, Mr. Faizatul Hazli and engineer Mr.Sharizul Anuar fully in charge for this new model. I am as an assistant for this group to conduct small responsibility for this new model in off tool stage. Since I join this group, I learned a lot of assembly process. Now I know how to assemble HTSL50 model. From this, I can know contain of the new model of HTSL50. As a conclusion, in S&O

Electronic Sdn Bhd they just follow 4 steps to create a new model or product. Apart from that, I learned how to design using software. I learned Power draw for 2D drawing and Pro engineer for 3D drawing. My supervisor was taught me how to use power draw and pro engineer software. These two applications will help me a lot in my future career.

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INDUSTRIAL TRAINING Furthermore, in UUM I was learned as theory about 5S system, just in time, Kaizen process and so on. But in S&O I can see the application of 5S in factory layout. The applications of 5S are listed below: Seiri (Sort out unnecessary item in the work place and discard them) o The classification should carry out by sorting the tool stage area base on the frequency used. The action at the source should always remain to budgeting, scheduling and implement it. For example, the basic regulations required are segregating all well and reject item according the model and labels. Seiton (Arrange necessary item in good order so that they can easily pick for use ) o The better system, the better works. a functional storage should carry out by analysis present situation, fixes the storage place and method and keep storage rules. For an example parts should be arranged for easy access according to model. Seiso (Clean work place so that is not dust on floor ,machine and equipment) o Seiso always create a spotless place. Cleaning mean that checking overall situation must always prevent defects and cleaning. For example, clean the place before and after work and do not sketch the factory surrounding and workplace. Seiketsu (Maintain high standard of housekeeping and work place at all time) o A good effort must always maintain in work place to create a maintenance schedule system in working environment. Shitsuke (Train people to follow good housekeeping discipline) o This activity is to train people always follow discipline in work place. For example the regulations, the lighting and plug must switch off after work or rest time, use pedestrian lane to canteen, come to work in time, wear proper uniform all the time and follow instruction from superior.

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INDUSTRIAL TRAINING From 6 months practicum in S&O I learned so many things about working environment and as a student I must attached to the working environment. I got know studying life style is totally different with working lifestyle. 6 months of practicum taught me a lot and learnt a lot. 5.2 MY RECOMMENDATIONS TO S&O ELECTRONIC SDN BHD 1. Student should be given an opportunity to choose training or giving a chance to train in different department. This is because they can gain more information and knowledge in various field of training. 2. Besides that R&D department staff always busy with their project in hand and no special department to train the trainee. So its better to give a chance for the student to expose more departments to learn more knowledge. By this the student not only can learn more knowledge but also determine which field or department is suitable for their future career. 3. An overview of sharp background and history already done on the first day of the orientation. This overview should be included brief descriptions of each department or section in this company. By this, we can know more about how the S&O produced a product and what product have been produced. Besides that, a house tour visit should be organized on the first day of the training so that trainee can know more about the factory. 4. A clear description of the training program needs to be attached with the confirmation letter to the student. This is because students need to know what department they are sending to and they can get to know whether the training program is related to them or not. 5. Trainee must given allowance during their practicum period. These can slightly help them to budget because not all of the trainees live in Sungai Petani and the transportation is a major problem as the trainees need to fill up their transport with petrol that cause a lot of money. The allowance also acts as a symbol of appreciation of the trainees hard work. This is because many of the trainees really work hard to help their group or support the line due to lack of manpower. The allowance gives a big meaning to the trainee as their hard work paid off.

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INDUSTRIAL TRAINING 6. I advise S&O personnel department, to exchange the smoking area. It is because the place is to near to the walkway for production factory. The smells from cigarettes can feel until the 1st factory walkway. Its not good for other workers. 7. For engineer in R&D engineer department should give sufficient time to contribute in new model. The time frame for new model is 3 months. The time frame makes them so busy and so rushing with 2 or 3 persons in each group. The time should modify to make them avoid from rushing. 8. In my experience in S&O I saw that, production engineer must cooperate with engineer department. It is because, sometimes the new model must do some modification but the production line already fully assembly it and pacput it at warehouse. Here have to rework. They complete part must reassemble again and rework it and assemble again and last package it. If production line or production engineer department gave sometime to R&D department, the assembly can make for 1 time only. Rework makes waste of time. 9. S&O should improve their design to attract customers attention. This is because customers view is important in the business field. By doing research on the competitors product can improve SHARPs product. For example the colour of design might be able to change. Most of the S&O products are silver and black colour and the shape are so formal. Some innovative design can attract customer.

10. The 4 steps are good to follow. But the time frame is too close to each and another. So the top management must review about the time frame of new model.

11. Last recommendation is must have strictly rules about no phone calls before 8.15am. It is because in my experience I saw that, while the morning meeting, the phones start to ring. Its like kind of disturbing to morning meeting. So the HR department must issue new rules for phone calls.

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INDUSTRIAL TRAINING 5.3 SWOT ANALISIS STRENGTH Design stage in S&O is most important stage that we need to draw a new model part using our imagination. Moreover design process is most important process in any factory because design process in need to produce a new product. I learned Power Draw (2D drawing) and Pro engineer that are useful for me in the future Discipline is very important in S&O. punctuation of every worker during their working hours make me more discipline on my daily activities WEAKNESS A proper schedule for trainee is important so that we can know what we have to do next. During the industrial training, no training schedule is given to trainee. No allowance to the trainees for their expenditure during training.

OPPORTUNITY I learned some injection molding process. Pro Engineer software widely use in many factory. I have learned it at this factory and this will give me more advantage when for a job. Trainee got chance to learn from mistake by doing rework

THREAT Trainee must provide training schedule so the trainee can follow the schedule smoothly if engineer is busy.

Table 10 - Swot Analysis

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CHAPTER 6
REFERENCES

1. S&O journal ,Kristal , march/April, issue No19, Printeligence (M) Sdn.Bhd 2. J.E Shigley & C.R Mishke, Mechanical Engineering Design, 5th edition, McGrawHill Companies.Inc, 1989. 3. Ng Teck Leng,Industrial Training Report University Technology Malaysia, 2005 4. GVU8th WWW user survey. (n.d). Retrieved April 20, 2011, from

http://en.wikipedia.org/wiki/New_product_development 5. GVU8th WWW user survey. (n.d). Retrieved April 20,2011, from

http://www.witiger.com/marketing/newproductdevelopment.htm 6. GVU8th WWW user survey. (n.d). Retrieved April 20,2011, from

http://www.slideshare.net/anicalena/new-product-development-process-diagram 7. GVU8th WWW user survey. (n.d). Retrieved May 14,2011, from

http://192.168.117.152/eng1/index.html 8. GVU8th WWW user survey. (n.d). Retrieved May 15 ,2010, from

http://www.sharp-world.com/corporate/info/his/h-company/ 9. We are Sharp monthly magazine 10. Sharps Library 11. http://www.sharp.com.my/philosophy.php

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CHAPTER 7
APPENDIX

Caliper is a device used to measure the distance between two opposing sides of object

2D drawing using Power Draw software

I assembly the subwoofers power Amp set

Power Amp

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Bar Code Scanner

PCB

Automatic tape sticker

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PWB Checker

Nichiban tape

Mecha Set

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Stencils of Silk Screen

Process of Drop test

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INFRONT OFF PWB

CORE SIDE OF PWB

Aging Test

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APPROVAL FORM

CHAMBER

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