DAIKIN

Internship PresentationInternship Presentation

Name: Mohamad Hafiz Abd Latif

Supervisor: Mr Khong Chun Fei

Date: 23rd of February 2017

Time: 10 am

Venue: Training room, Daikin Malaysia

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Table of contentsTable of contentsTittle…………………………………………………………………..1

Table of content……………………………………………………...2

Personal Information………………………………………………...3

Design and fabrication skills………………………………………. 4

Unit testing…………………………………………………………...10

Barashi day……………………………………..............................11

Time study…………………………………………………………...12

AGV project………………………………………………………….13

Coil tunnel for QC…………………………………………………...21

Stamping fabrication line………………………………………….. 23

Stock take……………………………………………………………24

Suggestion to the management………………………………….. 25

Feedback…………………………………………………………….26

Skills need to be improved…………………………………………27

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Personal InformationPersonal InformationName: Date of Birth:Mohamad Hafiz Abd Latif 31st May 1994

Education: Bachelor’s Degree in Mechanical EngineeringThe University of Sydney (March 2014 – November 2017)

South Australian MatriculationTaylors College Subang Jaya (July 2012 – November 2013)

- ATAR 91.90

Sijil Pelajaran Malaysia (January 2007 – November 2011)Pokok Sena Science School

- Straight A’s

Internship objective:To learn and utilize engineering knowledge and experience gained from university.To expose myself to real-work life and develop my career path asan engineer.

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Design and FabricationDesign and FabricationAssisting engineer by improvised recent equipments and facilities.

Objective: To support part supply for B3 line.

Before After

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Design skill (Solidworks)Design skill (Solidworks)

EXV controller bracket

Extensively developed my Solidworks skill throughout the designing process

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Design skill (Solidworks)Design skill (Solidworks)

Coil Tunnel to improve leak test efficiency

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Design skill (Solidworks)Design skill (Solidworks)

Mirror holder to check hairpin end condition

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Design skill (Solidworks)Design skill (Solidworks)

U-bend jig

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Fabrication(Machining)Fabrication(Machining)

1) Sawing skills - using jig saw machine.

2) Drilling skills - using bench drilling machine and hand drill

machine.

3) Grinding skills – using hand grinding machine

4) Pipe joint assembly process skills

1

23

1

4

Skills learnt throughout the fabrication process:

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Unit TestingUnit Testing

B1 Test Room (0.5 – 1.5 hp)

B2 Test Room (1.5 – 3.0 hp)

Refrigerant R410A R32

R410AR22

Frequency 50 Hz 60 Hz50 Hz

New 60 Hz unit was requested by customer from Philipines.

Since the new product cannot be tested at B1 because the facilities is not set up yet, hence it was tested at B2.

Hypothesis:The compressor could not pull the refrigerant back due to the smaller sizeand the dummy air cond in B2 test room is big. Hence, low charge will occur.

Results:Hypothesis accepted.

Aim:To test whether new B1 unit can run at B2 line.

Unit Trolley Before After Difference

1 19 21.41 kg 21.24 kg 0.17 kg

2 17 20.40 kg 20.25 kg 0.15 kg

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Barashi dayBarashi day

Review and compare Daikin’s product design with other competitors.

Achievement:Developed analysis skill

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Time StudyTime Study

Assisting engineers to carry out time study for new B3 Line.

Objective:To investigate the set up of new line (Production engineering)

Takt time: 18 seconds

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AGV project for B3AGV project for B3Involved in the information sharing meeting with GMI(Global Manufacturing Improvement) and production representative.

Objective: • To implement AGV on B3 line in order to do kaizen(improvement)

- Parts supply improvement- Reduce man power- Reduce area- Reduce parts stock/WIP

• To understand B3 Line current situation in order to do kaizen(improvement) on the Line.

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Proposal of AGV parts transfer routeProposal of AGV parts transfer routePa

ints

hop

3

Paneling Area Base Pan Assy

Parts Picking Area

Insu

latio

n Ar

ea

TransitArea

Target Takt Time : 18 secWorking hours : 2 shift

156m

AGV speed max : 60m/minConsider the turning points, average speed : 50m/minFor distance 156m, AGV takes 3.12 mins to travel. (If 2 ways : 6.24mins)

Based on this, each trolley must have minimum 21 pcs WIP (21pcs x 18 sec = 378 sec = 6.3 mins)

If use 2 AGV, the WIP quantity can be reduced to half.But, the AGV route must be single loop design which will takes more space for the travelling route.

SOURCE: GMI, 2017

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Time Study for AGV project Time Study for AGV project Time observation chart

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Time Study for AGV project Time Study for AGV project Standard work chart

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Time Study for AGV project Time Study for AGV project

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AREA STUDY(PREPARATION AREA)AREA STUDY(PREPARATION AREA)

Assisting GMI to carry out area study for new B3 line.

Objective: Reduce area

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AREA STUDY(PANELLING AREA)AREA STUDY(PANELLING AREA)

Assisting GMI to carry out area study for new B3 line.

Objective: Reduce area

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AREA STUDY(INSULATION AREA)AREA STUDY(INSULATION AREA)

Assisting GMI to carry out area study for new B3 line.

Objective: Reduce area

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Coil TunnelCoil TunnelObjective: 1) To enhance leaking detection at Helium Leak Test Station2) To ensure no leaking coil escape to the next process

Source: QC, 2017

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Improvement approachImprovement approach1. Installation of Helium Reclaim machine for off-line station. Objective: To ease coil rework process without interrupting the online production.

2. Installation of “coil tunnel/helium accumulator” (currently working on it) Objective : To overcome u-bend tip micro leakage problem that could not detect by helium sniffer machine.

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Stamping fabrication lineStamping fabrication line

Top panel

Front panel Base pan

Service panelLine 1(300T)

Line 2(250T)

Line 3(200T)

Line 4(200T)

Top panel x xFront panel x xService panel xSide panel xBase pan x

SL1015FFR

Side panel

Blanking Forming Side piercing Caulkling

Stamping Process for Base pan

Objective: Learn the process flow of stamping fabrication line

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Stock takeStock take

Objective:•To be up to date on how much stock and materials Daikin has on things.

•To maintain knowledge of the inventory.

Follow engineer to do stock take in order to understand better the process ofStock take.

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FeedbackFeedback

Positive:

• High allowance• Very interactive colleague and manager• Very friendly IE workshop staff• Developed communication skill among different level of ages

Negative:

• Lack of productivity, always drag work and not punctual (IE workshop)• Problem in communicate with the operator• Revised the orientation content for intern (take out the CA member and executive Induction)

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Skills that I need to be improvedSkills that I need to be improved

Technical skills

• Microsoft excel• Solidworks• Autocad

Soft skills

• Communication skills• Confidence• Planning and organizing skills