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ABSTRACT
Students are required to undergo industrial training for 12 weeks as part of the
requirement to complete the 4 years course for the Bachelor of Engineering (Hons) Mechanical,
Universiti Teknologi MARA (UiTM). The attachment was held during the semester break of the
6th semester of the study. During the 12 weeks period of training, students will be supervised
and monitored by one supervisor. The Industrial Training was completed at Alps Electronics
SDN. BHD. Generally, ALPS is the manufacturer of electronic parts for most consumer cars and
some motocycles here in Malaysia. During the 12 weeks of training, the working environment
was successfully exposed in order to gain more experience and knowledge. A combination of
several tasks and projects were assigned which consists of technical and managerial aspects. The
scope of the assigned jobs will be discussed later throughout this Industrial Training report. All
of the related materials has been gathered and compiled and the report will focus on the projects
and processes that were involved during the engagement of the assigned tasks.

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1. Abstract 1
2. Introduction 2
3. Indutrial Environment 7
4. Industrial Experience 11
5. Industrial Project 18
6. Summary 21
7. Reference 22

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1)INTRODUCTION
1.1 COMPANY HISTORY
Alps Electric Co., Ltd.
The company first founded in 1948 as Kataoka Electric Co., Ltd in conjuction to the founder’s
name, Katsutaro Kataoka. The name was changed to Alps Electric Co. Ltd in December 1969.
Alps Electric currently possesses 25 companies all over the globe including Thailand,
India,Korea and China.
Alps Electric Companies
 Alps Green Devices Co., Ltd.
 Alps Electric(North America), Inc.
 Cirque Corporation
 Alps Electric Europe Gmbh
 Alps Electric(Ireland)Limited
 Alps Electric Czech, S.R.O.
 Alps Electric Korea Co., Ltd.
 Alps Electric(S) Pte. Ltd.
 Alps Electric(Malaysia)Sdn. Bhd.
 Alps Electric(Thailand) Co., Ltd.
 Alps Electric(India) Pvt. Ltd.
 Alps(China)Co., Ltd.
 Alps Shanghai International Trading Co., Ltd.
 Alps Communication Devices Technology(Shanghai)Co., Ltd.
 Dalian Alps Electronics Co., Ltd.
 Dandong Alps Electronics Co., Ltd.
 Tianjin Alps Electronics Co., Ltd.
 Ningbo Alps Elecronics Co., Ltd.
 Wuxi Alps Electronics Co., Ltd.
 Alps Electronics Hong Kong Ltd.

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 Dongguan Alps Electronics Co., Ltd.
 Alps Electronics Taiwan Co., Ltd.
 Shenyang Xikang Alps Technologies Co., Ltd.
 Kurikoma Electronics Co., Ltd.
1.2 STRUCTURE AND RESEARCH & DEVELOPMENT EXPENDITURE
Development of basic and advanced
technology takes place in Japan, though
designs of different product varieties
reflecting the needs of particular customers
and markets are developed regionally. Under
this format they promote global
standardization of technologies and products.
They also actively engage in joint research
with universities and research institutions around the world and development through
partnerships with other companies.
Technology
Alps Electric stands at the forefront of value creation, forever turning out original products to
react market needs and conditions. Fusion and advancement of technology is pivotal here as
mechatronics technologies amassed over the years are merged with process technologies
supporting functional device development and materials technologies used to develop and
identify the best materials.
IC design - Alps develops IP for modules and sensor circuits in an effort to meet the diverse
needs of manufacturers
Evaluation/Simulation – Alps uses data gethered over the years and software developed in-house
to create optimal products in short period of time

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Design/assembly – Alps has fully automated assembly and production of voice coil motors,
which are compact and yet drive even large diameter lenses
Optical design/molding – Alps delivers superior optical products using optical design and
molding technology to limit light interference and realize high transmittance
1.3 OBJECTIVES OF PRACTICAL TRAINING
Industrial training is one of the requirements for Bachelor of Engineering (Hons) Mechanical,
Universiti Teknologi MARA (UiTM). The objectives are:
i. To adapt readily to real-life working environment and practice right work attitude
Students should be able to adapt to actual working environment and learn on how to work in
a team.
ii. To apply knowledge learnt, gained new skills and be aware of current technologies
Students should be able to apply all the knowledge learnt into the industrial works as well as
gaining new skills during the industrial training.
iii. To identify the industrial problems and able to suggest possible solutions
Students are able to identify and analyse any problem that occurred during work and give any
possible suggestion in order to solve the problems.
iv. To facilitate students to potential employers
To take opportunities to show valuable characters to the employers and can contribute to the
progress of company in the future.

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1.4 SCOPE OF TRAINING
During the 12 weeks of industrial training, the appointed position was as a trainee under the
Engineering section in Nilai Engineering Department. The task was to improvise the work
envinroment for production throughout the training period. The actual working principle and
industrial practice was experienced as an extension to the theoretical knowledge acquired during
the study period.
1.2.1 Tooling Department
Learning about the role of a spare part engineer, it involves taking care of the spare parts and
program management. Any issues related about machine parts will be the spare part engineer’s
responsibility along with the related documentation. The documentation that is related to the
tooling engineer are Work Instruction Manual (WIM), Tool Order, Request Form (RF), Parts
Defect Report, and machine’s drawing.
MAJOR SCOPE OF TRAINING
1. PROCESS ENINEERING
2. DESIGN ENGINEERING
3. MECHANICAL ASSEMBLY ENGINEERING
4. ELECTRICAL ENGINEERING
5. PROGRAMMING ENGINEERING

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2) INDUSTRIAL ENVIRONMENT
2.1 TEAMWORK
Teamwork represents a cooperative and coordinated group of peoples working together
as a team with a common interest. In line with the vision of ALPS ELECTRICAL
(MALAYSIA)SDN BHD unit works to be the best-in-class in asset integrity and engineering.
The unit consisting of various teams collaborates together in ensuring effective completion of
work and project management. Thus, a good teamwork is very essential in this unit.
The team comprises of project management team, engineering team, construction team and
procurement team. Each and every one play a significant role in getting work done. Each team
has its own respective roles and responsibility and this leads to a well-formed organization. A
strong teamwork is displayed in the Engineering Services unit as everyone is running towards the
same objective and has a clear and precise goal. Since the unit manages project that involves
multidiscipline, all related engineering discipline member work as a team to ensure the projects
requirements are met.
Cooperation among the disciplines is vital in ensuring the work is carried out according to the
schedule. Department meetings and discussions are carried out to get updates for task that has
been completed and also for pending work. Opinions on improvement and strategy to overcome
challenges are proposed. Effective communication is the key to a successful teamwork. Ability
to communicate well allows a better understanding among the team. Strong leadership skills
displayed contribute to the effectiveness of teamwork when executing work. Under the guidance
and supervision of a great leader, work is completed in an efficient manner.
2.2 IMPLEMENTATION OF 5S
One of the methods of determining an organisations approach to its business is to evaluate its
workplace organisation capability & visual management standards.
5S engages employee through the use of Standards and Discipline. It is not just about
housekeeping, but concentrating on maintaining the standards & discipline to manage
envinronment product quality.

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 Seiri
Sorting, keep the necessary in work area, dispose or keep in a distant storage area less frequently
used items, unneeded items are discarded. Seiri fights the habit to keep things because they may
be useful someday. Seiri helps to keep work area tidy, improves searching and fetching
efficiency, and generally clears much space. Seiri is also excellent way to gain valuable floor
space and eliminate old broken tools, obsolete jigs and fixtures, scrap and excess raw material.
 Seiton
Systematic arrangement for the most efficient and effective retrieval. A good example of Seiton
is the tool panel. Effective Seiton can be achieved by painting floors to visualize the dirt,
outlining work areas and locations, shadow tool boards. For improving changeover time with
reduce machine downtime throught Total Productive Maintenance (TPM) it is necessary to have
tools at hand.
 Seiso
Cleaning. After the first thorough cleaning when implementing 5S, daily follow-up cleaning is
necessary in order to sustain this improvement. Cleanliness is also helpful to notice damages on
equipment such as leaks, breakage and misalignment. These minor damages, if left unattended,
could lead to equipment failure and loss of production. Regular cleaning is a type of inspection.
Seiso is an important part of basic TPM; Total Productive Maintenance and Safety matter
through cleanliness is obvious.
 Seiketsu
Standardizing. Once the first three S have been implemented, it should be set as a standard so to
keep these good practice work area. Without it, the situation will deteriorate right back to old
habits. Have an easy-to-follow standards and develop a structure to support it. Allow employees
to join the development of such standards.

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 Shitsuke
Finally, to keep first 4 S alive, it is necessary to keep educating people maintaining standards. By
setting up a formal system; with display of results, follow-up, the now complete 5S get insured to
live, and be expanded beyond their initial limits, in an ongoing improvement way; the Kaizen
way.
2.3 OCCUPATIONAL SAFETY AND HEALTH
ALPS ELECTICAL as one of the most important company in Negeri Sembilan is very firm in
providing safe and healthy workplace for all employees working with its facilities and to
minimize the impact of its operations to the environment. Every ALPS group employee must
meticulously follow all the HSE requirements, measures, work rules and standard operating
procedures set out in manuals, handbooks and documents issued by ALPS as amended and
updated from time-to-time in all applicable laws and regulations.
ALPS ELECTRICAL Policy on Health, Safety and Environment
ALPS ELECTRICAL (MALAYSIA) Sdn. Bhd. is very committed to Health, Safety and
Environment (HSE) and shall take reasonable and practicable steps to eliminate, prevent and
minimize the risk of personal injury, occupational illnesses and damage to properties.
Besides that, they must implement effective risk control measures in all their activities; including
operations covering acquisition, exploration, development, production and abandonment which
will eliminate, prevent or reduce risks to a level as low as reasonably practicable. Moreover, part
of business philosophy and cultivate a desired HSE culture, they build an effective and resilient
HSE Management System as an integral part.
In addition, they provide competent workforce, adequate resources and organization in all their
activities in ensuring a safe environment at the workplace. Besides that, they promote continuous
improvement in HSE performance. Lastly, effective crisis management and emergency response
capabilities are also must be establish in all their operations.

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2.4 PERSONAL PROTECTIVE EQUIPMENT (PPE)
Personal protective equipment, commonly referred to as "PPE", is equipment worn to minimize
exposure to serious workplace injuries and illnesses. These injuries and illnesses may result from
workplace hazards. Hazards exist in every workplace in many different forms such as sharp
edges, falling objects, flying sparks, chemicals, noise and a myriad of other potentially
dangerous situations. Safety and Health Department takes an active role in providing personal
protective equipment for their employees and ensure that they are being used by them. PPE may
include items such as gloves, safety glasses and shoes, earplugs or muffs, hard hats, respirators,
or coveralls, vests and full body suits.
2.5 STOP WORK POLICY
Stop Work Policy of ALPS ELECTRICAL (MALAYSIA) Sdn. Bhd. grants every employee the
right to invoke a stop work order when there is an imminent and real threat which can physically
endanger them and others or cause adverse impact to the environment.
The management fully supports the decision of its employees in the diligent execution of this
policy. When there is doubt on whether work should continue, employees including contractor
staff, should promptly notify their immediate supervisor for assessment of the hazardous
condition.
Drug and Alcohol Policy
In accordance with Health, Safety and Environment Policy, ALPS ELECTRIC Sdn Bhd
recognizes that any drug and alcohol abuse will affect the employee’s work performance and can
be a threat to the company’s operations. It is the company’s policy that its employees and
workplaces are free from drug and alcohol abuses.
The company requires all its employees, contractors and others to strictly adhere to this
policy at all times. Joint venture partners of the company are expected to this policy at all times.
Joint venture partners of the company are expected to implement an effective drug and alcohol
programme, which is in line with the industry’s best practice.

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3) INDUSTRIAL EXPERIENCE
Throughout the training, the trainee was attached with the Nilai Engineering Department
(ENL), a department under Maintenanceor support Team in Nilai with advidor of Nilai
Engineering Department, Mr Yichijo from Japan. Working with this department, many
experience technical work and knowledge are gain during these 12 weeks. All the activity are
have the same objective which is to ensure all the machine equipment such as process, design,
mechanical, electrical and programming are in good condition and fully function well in order
keep the productivity of the line keep maintain to supply to the customer of the ALPS
ELECTRICAL (MALAYSIA) sdn bhd.
3.1 INTERNATIONAL STANDARDS
 ISO 9001
ISO 9001 sets out the criteria for a quality management system and is the only standard in the
family that can be certified to. It can be used by any organization, large or small, regardless of its
field of activity. Alps was certified for its department’s procedure,work instruction procedure
and work instruction manual
 ISO 14001
ISO 14001 sets out the criteria for an environmental management system and can be certified to.
It maps out a framework that Alps can follow to set up an effective environmental management
system.
 ISO/TS 16949
ISO/TS 16949 defines the quality management system requirements for the design and
development, production and, when relevant, installation and service of automotive-related
products.
This industrial training provides an imperative platform for practicing effective
communication and developing communication skills. Having excellent communication skills

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help to be successful in work and to deal with conflicts happening in workplace. Besides that,
effective communication skills are vital and significant in improving work and personal
relationships among the colleagues. Good communication skills reflect how well a person
expresses themselves. Both verbal and nonverbal communication skills are essential in leading to
a good and efficient communication.
All the activities that have been done are followed the working philosophy. There will be
specific notification to notify all the staff what the activity that need to done for that day. The
activity could be Preventive Maintenance, Reactive Maintenance or defect that have been noted
during the visual inspection by staff or noted by operation department for attends. There also an
activity where the task needs to be done at warehouse where to checking the ordered item that
has been arrived. There are several job engineer that can been obtain a experience such as:
 Process Engineer
 Design Engineer
 Mechanical assembly Engineer
 Electrical Engineer
 Programming Engineer
 Mechanical setting Engineer

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3.2 PROCESS ENGINEER
Before the department request about a machine, there are some process engineer needs to study
the process first. For example the request is about from the manual jig SDKZ machine to semi
auto SDKZ machine. So, in this case the process engineer needs to study the process, cycle time,
no of workstations and layout of the machine.
Figure 1: Wafer insert manual jig
Figure 2: Grease on the cam
Process engineer need to identified either they can improve the efficiency of the machine,
identified either can decrease the process needed by the machine or reduced the cycle time
needed by the machine.

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3.3 DESIGN ENGINEER
After the process engineer do their jobs, design engineer will take over the manufacturing
of the machine. Their jobs are to generate the 3d cad drawing by using Solidwork software.
Basically, design engineer need to know everything about the machine. It is because they have to
analyse the suitable part which is use in the machine. For example, for a SCCL machine in the
insert of spring, they need to use laser sensor. It is because the laser sensor only can detect the
present of spring.
Figure 3: Example of 3D CAD Drawing
Furthermore, there are two types of part to make of full machine which is standard part and
mechanical part. The difference between mechanical and standard part is mechanical part made
in Malaysia while standard part made in Japan. There are few examples of vendor in Malaysia
such as:
 Mastool
 Gms
 Auto
 Kanzen
There are few vendors from Japan:
 Keyence (camera)
 Omron (sensor)
 Misumi (standard part)
 SMC (vacuum,hose,cylinder)

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3.4 MECHANICAL ASSEMBLY ENGINEER
After design engineer generate the 3d cad and do their analysis, the part will arrived to be
assembled. In this case, assembly engineer will do their jobs. Engineer had done about their
analysis about mechanical parts, and find out that the quality of the vendors is different. The
best one is Mastools vendor. Assembly engineer would start their job by using a 3d drawing.
Figure 4: Assembly of the jig
The assembly of the machine is around 2 to 3 months. It depends on the mechanical and standard
part that was ordered. The part that was imported from the Japan takes time too long. While the
machine was assembled, there are some parts need to modified first. It is because to prevent the
jig from produce a NG product.
Figure 5: Machine

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3.5 ELECTRICAL ENGINEER
When the jig is about 90% to complete, the electrical engineer will take part in this job.
They will do some electrical wiring to the jig. In this scope, I have learned a lot of thing such as
how to use multimeter, fuse in the plug, wiring of 120v and 240 v of switch and connecting a
wiring from plc to the jig or machine.
Figure 6: Wiring the Plug
There are three types of wire in the plug which is live, neutral and earth. The colour of earth wire
is green which is in common colour. While for a live wire, the colour is sometimes black or
chocolate. For a neutral wire, the colour is almost blue in this country. Earth wire is on top of the
plug, while live is on the right where is the fuse located.
Figure 7: Wiring to the PLC
Electrical engineer will connect the wire from jig to the plc by read it from electrical
drawing. The drawing actually was imported from the Japan, so they know to connect it
properly.

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3.6 PROGRAMMING ENGINEER
After the electrical engineering have done about their jobs, the programming engineer
next will continue their works. in this case, the jig need to connected with plc. the type of
pragramming used is ladder diagram.
Figure 8: Ladder diagram
There are few types of plc in ladder diagram such as:
 normally open (no)
 normally closed (nc)
 relay
 timer
 counter
Basically, if there have the old machine they just need to copy and paste the ladder diagram
program.

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4) INDUSTRIAL PROJECTS
4.1 Engineering Section
Objective
 To learn the process of the machine
 To design the part and assembly complete it
 To assembly the jig properly so there have no more problem
 To learn the electrical part
 To learn how the program can make the machine move
 To learn and implement the concept of KAIZEN for improving production quality
PIC : Mr. Chin Kar Long (Engineering section Manager)
4.2 SDKZ MACHINE ALLIGNMENT SETTING
Objective
 To make sure the SDKZ machine is working properly
 The produt is follow the Japan specifications
 To reduce the cycle time of the machine
 To increase the quantity of product
Problem
 Production drops for new operators
 Spring insert into the rotator
 The quality of the grease is not follow the specification
 Contact blade sometimes not insert correctly
 The upper case and lower case sometimes cannot assembled correctly
Solution
 Do a kaizen to the part of the machine
 Do an analysis to the mold

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4.2.1 PROJECT : GREASE ON CAM
Figure 9 : Grease on Sdkz machine
 At first, the quantity of the grease on the cam was 5. The specification of Japan is 8.
 Pragramming engineer try to set the timing in the plc.
 Design engineer do some kaizen to the cylinder part which is try to shorten the cylinder
holder.
 We try to run the machine so many times and record the result.
Figure 10 : Grease on cam
 Engineers identified that in 11 pallets that run, there are around 3 to 4 pallets that produce
not good quality of grease.
 The reason of that quality is cause by the timing of the program. The cylinder that moves
down very fast are produce the quality that is not good enough.

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4.2.2 PROJECT: SPRING INSERTION
Figure 11 : Insert Spring sdkz machine
 The spring need to insert to the rotator. Continued by inserted of ball to the rotator.
 There have 6 cavity of rotator which is A, B ,C ,D ,E and F. the suitable rotator that can
used in semiauto SDKZ machine is cavity C only.
 Engineer need to do kaizen so this kind of machine can use all of the cavity.
 At first, the machine run 55 pallets of cavity C. the result shows only 4 pallets are
missing their spring.
Figure 12 : Spring in the Rotator
 The latest result shown that the missing of the spring to the rotator is decrease.

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5) SUMMARY
Finishing the whole 3 months as Industrial Trainee is not as a piece of cake. During this
time, all trainees have to learn a real problem that happen in factory, learning new thing in very
different types of environment compare to lecture period. It is surely need the fully commitment
and hard work on the first day call as trainee until complete the training period. After I have done
my industrial training at ALPS ELECTRIC (MALAYSIA) SDN BHD, I can conclude that I have
learn a lot of things. There are so many thing that I can applied in the factory by using
knowledge I get from UiTM.
While follow the industrial training, I have been work as a process, design, mechanical
assembly, electrical, programming and mechanical setting engineer. I can know the flow how the
mcahine can produced from A to Z. This helps much to improve the communication skills and
understand the communication between different level of executive and staff here. Respects also
one of the values that learn here where student has to respect executive and staff here as well
Besides thought by fields work, student also trains on the soft skills which refer to the
communication as how they respect their family and lecturers. Other than that, working in a team
also a good value here as every day and each task or job given by supervisor was solved and
trouble shoot with technician team here. This creates a good relation among technician team with
student and helps in smoothing the working task.

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6) REFERENCES
 Industrial training student logbook uitm
 www.keyence
 https://www.ia.omron.com/
 http://www.misumi-europe.com/en/customer-service/request-catalog
 Manager of Nilai Engineering, Mr zamri 0199199403