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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 BHD’s ACTIVITIES..............................................7
1.4 POLICY OF SHARP & ONKYO ELECTRONIC (M) SDN BHD ...................................8
1.5 SHARP’S BUSINESS PHILOSOPHY AND BUSINEDD CREED..................................9
1.6 SHARP’S THINK GREEN POLICY .............................................................................10
1.7 SHARP & ONKYO ELECTRONIC’S FINANCIAL STATEMENT..............................10
1.8 S&O ORGANIZATIONAL CHART..............................................................................11
1.9 R&D ENGINEERING DEPARTMENT ORGANIZATION CHART ............................12
1.9 SHARP & ONKYO ELECTRONIC’S 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 SHARP…………………………………………………………2
TABLE 2 – HISTORY OF S&O ELECTRONIC SDN BHD……………………………….6
TABLE 3 – S&O ACTIVITIES………………………………………………………………7
TABLE 4 – S&O ORGANOZATION CHART……………………………………………11
TABLE 5 – WORKING HOURS & REST TIME…………………………………………...13
TABLE 6 – LIST OF PRODUCTS………………………………………………………….14
TABLE 7 – EXPORT STATISTIC BY DESTINATION……………………………………14
TABLE 8 – HIGH TEMPERATURE CONDOTION………………………………………..28
TABLE 9 – DROPPING ORDER……………………………………………………………31
TABLE 10 – SWOT ANALYSIS…………………………………………………………….62
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LIST OF FIGURE
FIGURE 1 - SHARP LOGO…………………………………………………………………1
FIGURE 2 – MR.TOKUJI HAYAKAWA……………………………………………………1
FIGURE 3 – SHARP’S 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 PROCESS…………………22
FIGURE 9 – O JI STAGE…………………………………………………………………….23
FIGURE 10 – HIGH OR LOW TEMPERATURE CONDITION…………………………30
FIGURE 11 – NOISE TEST………………………………………………………………….33
FIGURE 12 – VIBRATION TEST…………………………………………………………33
FIGURE 13 – BAR CODE…………………………………………………………………36
FIGURE 14 – REMOTE CONTROL SPECIFICATION……………………………………36
FIGURE 15 – STEEL RULER SCRATCH TEST…………………………………………..37
FIGURE 16 – WET CLOTH TEST………………………………………………………….38
FIGURE 17 – METHOD OF RUBBING TEST……………………………………………38
FIGURE 18 – RUBBING TEST……………………………………………………………39
FIGURE 19 – METHOD OF NICHIBAN TEST……………………………………………39
FIGURE 20 – METHOD OF CROSS CUT TEST…………………………………………40
FIGURE 21 – CROSS CUT TEST…………………………………………………………...40
FIGURE 22 – METHOD OF MITSUBISHI PENCIL SCRATCH TEST…………………40
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 1……………………………………………………………………53
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FIGURE 28 – STAGE 2……………………………………………………………………55
FIGURE 29 – STAGE 3……………………………………………………………………55
FIGURE 30 – STAGE 4……………………………………………………………………55
FIGURE 31 – STAGE 5……………………………………………………………………56
FIGURE 32 – STAGE 6……………………………………………………………………57
FIGURE 33 – STAGE 7……………………………………………………………………..57
FIGURE 34 – LEFT VIEW…………………………………………………………………58
FIGURE 35 – FRONT VIEW………………………………………………………………...59
FIGURE 36 – RIGHT VIEW…………………………………………………………………59
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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 - SHARP’s 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 • Sharp’s founder, Tokuji Hayakawa establishes a metal works in Tokyo.
1915 • Tokuji Hayakawa invents the Ever-Sharp Pencil.
1925 • Assembly and marketing of crystal radio sets.
• Radio broadcasting begins in Japan.
1929 • Production of the first Sharp-Dyne AC-powered vacuum-tube radio sets.
1951 • Development of a prototype television set.
1953 • Mass production of television sets to coincide with Japan’s first television
broadcasts.
1960 • Mass production of colour television sets.
• Colour television broadcasting begins in Japan.
1962 • Mass production of microwave ovens.
1963 • Mass production of solar cells and silicon based photovoltaic cells.
1964 • Development and mass production of the world’s first all-transistor
desktop calculator.
1966 • Development of electronic desktop calculators incorporating integrated
circuits.
• Marketing of Japan’s first microwave with turntable
1969 • Development of ELSI chips.
• Marketing of electronic calculators incorporating ELSIs.
1970 • Akira Saeki becomes president.
• Changes name from Hayakawa Electric Industry Corporation to Sharp
Corporation. Gray
• Establishes Corporate Development Center.
• Mass production of LSIs.
1973 • Mass production of liquid crystal displays.
• Development of the world’s first COS electronic calculator incorporating
a liquid crystal display.
1974 • Development of a thin-filmed EL element.
1975 • Development of 9 mm-thin electronic calculators and foldable
incorporating electronic circuit films.
1976 • Introduction of solar-powered calculators.
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• World’s first mass production of 44-pin CMOS LSIs using a film carrier.
• Development of ultra thin (7 mm) electronic calculators with CMOS
LSIs.
1977 • Introduction of 5 mm-thin card-sized, sensor-touch electronic calculators.
1979 • 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 world’s first super-thin (1.6 mm)
card-sized calculator.
1981 • Development of the world’s first long-life laser diode.
• Introduction of portable VCRs for camera/television recording.
1982 • Introduction of pocket computers using BASIC language.
• Introduction of the world’s first combination personal
computer/television set.
1983 • World’s 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, 160-
pixel, 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 world’s first 14-inch large-screen, thin-profile, and
high-definition colour TFT liquid crystal display unit.
1989 • Introduction of the world’s 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.
1990 • Development of the world’s first full-colour desktop facsimile.
• Introduction of a home copier / facsimile.
1991 • 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.
1992 • 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 world’s first liquid crystal display
View cam.
1993 • Development and introduction of the world’s 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.
1994 • 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.
1995 • Development of the world’s largest (28-inch) TFT direct-view colour
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liquid crystal display unit.
• Development and introduction of the world’s 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 world’s first 28-inch wide-screen liquid crystal
display television compatible with digital hi-vision broadcasts.
2003 • Introduction of world’s first 37-inch LCD TV with built-in terrestrial
digital-HDTV tuner.
• Development of industry’s 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 world’s largest full-spec
hi-definition, hi-resolution LCD TV.
2006 • Opening of SHARP Kameyama Plant No. 2, the world’s 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
Table 2 – History of Sharp & Onkyo Electronic (M) Sdn.Bhd
Company Contents
S&O (formerly
known as SRC)
Figure 1.4 – S&O
Plant
Name:
State:
Established:
Business
History:
Future
Deployment:
Sharp & Onkyo Electronics (M) Sdn. Bhd.
(Formerly known as Sharp-Roxy Corporation (M)
Sdn. Bhd.)
Kedah
1974 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
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1.3.1 S&O ELECTRONICS (M) SDN BHD’s ACTIVITIES
Year Activities / Production
1974 SRC were established.
1976 Production of portable radio started.
1977 Production of mono cassette radio.
1979 Music centre started.
1981 Auto insert machine were introduced.
Production of radio cassette recorder stereo.
2nd factory construction finished.
1982 Production of car audio.
1984 ZD (Zero Defect) activities were launched.
1985 Chip insert machine were introduced.
1986 Self development model were launched.
QCC activities were introduced.
1987 2nd factory development were finished.
1988 CD (Compact Disc) production was launched.
1989 Construction of warehouse was completed.
1990 3rd factory completed.
1991 CD pick up was completed.
1992 ISO 9002 BSI Certificate was awarded.
1993 Production of facsimile.
1995 Production of cordless telephone was launched for overseas production.
1996 Production of cordless telephone was launched for Japan production.
1997 Cordless facsimile for Japan model was launched.
1998 ISO 9001 BSI Certificate was awarded.
Production of MD (Mini Disc) started.
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 customer’s 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 company’s 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 company’s policy
on quality.
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1.5 SHARP’S 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 SHARP’S THINK GREEN POLICY
Figure 3 - SHARP’s Think Green Policy
1.7 SHARP & ONKYO ELECTRONIC’S FINANCIAL STATEMENT
Figure 4 – Percentages of shareholders of S & O Electronics
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The company’s 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
Administration
Director / Senior General Manager of
Production / Production Engineering (P.E.)
Mr. Asami
Mr. Keiji Shibasaki
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)
MANAGER
ASSISTANT
MANAGER
SENIOR
ENGINEER
ENGINEER
ASSISTANT
ENGINEER
TECHNICIAN
CLERK
SENIOR
MANAGER
(ELECTRICAL)
MANAGER
ASSISTANT
MANAGER
SENIOR
ENGINEER
ENGINEER
ASSISTANT
ENGINEER
TECHNICIAN
CLERK
CONSULTANT
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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, non-
production 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 non-
production 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.
Table 5 – Working Hours and Rest Time
Start Lunch / Tea Time Finish
Monday – Thursday Friday Mond
ay –
Thurs
day
Friday
1st Factory
(Onkyo)
07:55
AM
10:00 AM – 10:10AM
12:00 PM – 12:40 PM
03:00 PM – 03:10 PM
10:00 AM – 10:10AM
01:10 PM - 02:20 PM
03:30 PM – 03:40 PM
05:30
PM
05:35
PM
2nd
Factory
( sharp)
07:55
AM
10:15 AM – 10:25AM
12:30 PM – 01:10 PM
03:15 PM – 03:25 PM
10:15 AM – 10:25AM
01:10 PM - 02:20 PM
03:45 PM – 03:55 PM
05:30
PM
05:35
PM
Office 07:55
AM
10:30 AM – 10:40AM
12:30 PM – 01:10 PM
03:30 PM – 03:40 PM
10:30 AM – 10:40AM
01:10 PM - 02:20 PM
04:00 PM – 04:10 PM
05:30
PM
05:35
PM
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1.9 SHARP & ONKYO ELECTRONIC’S 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 Products
Finished Goods 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 2006 2007 2008
USA, Canada 21% 14% 10% 7%
Europe 33% 56% 62% 61%
Japan 16% 11% 9% 8%
Asean 8% 5% 3% 3%
Malaysia 9% 5% 8% 11%
Others 13% 9% 8% 10%
Total 100% 100% 100% 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:
Ø How S&O develop a new Model (product) begins from idea generate until mass
production.
Ø 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 information’s
about the studies.
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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
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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
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information’s 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 information’s 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 “We’re 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
don’t 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:
Figure 8 – 4 stages in new model development
OFF – TOOL
PRE- PRODUCTION
“O” JI STAGE
MASS PRODUCTION
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4.1.1 ‘0’ JI STAGE (ZERO STAGE)
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
NEW PRODUCT
PLANNING OUTLINE
MARKET SURVEY
ISSUE DRAWING
FROM PRODUCT
PLAN
DEPARTMENT
COST STUDY TOTAL PLAN
QUANTITY
DEVELOPMENT
SCHEDULE
LIASE WITH CUSTOMER
ON ANY CLARIFICATION
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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
• Central & south America
• Brazil
• Argentina
EUROPE
• Europe (Germany base)
• Northern Europe
• U.K
• East Europe
• Russia
OCEANIA
• Australia
• New Zealand
ASEAN
• Malaysia
• Philippines
• Thailand
• Indonesia
• Singapore
• Hong Kong
• Taiwan
• Korea
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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. It’s
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 it’s 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 department’s 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 consumer’s 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
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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 65°C
Time Over 30 Hours
All knobs Packing condition which is written in packing working manual
Weight 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.
h
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
65°C 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 product’s
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
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the set such Japan, the temperature is set for the low is -10˚C and the high temperature is
65˚C.
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
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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.
Table 9 - Drop Test’s 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
Order Dropping place
1 Standard corner
2 Short length edge which is linked with standard corner
3 Middle length edge which is linked with standard corner
4 Long length edge which is linked with standard corner
5 Most small face which has standard corner
6 Opposite face of 5
7 Middle face which has standard corner
8 Opposite face of 7
9 Most big face which has standard corner
10 Opposite face of 9
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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.
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 Newton’s 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.
G= a/g
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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 (can’t 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
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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
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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 TV’s 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 test’s 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 competitor’s models and current models. There are some
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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 don’t 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.
Figure 15- steel ruler scratch test
2. Migration 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.
Before Test After Test
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Figure 16 – Wet cloth test
4. Sunshine 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/cm². 65 º 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/cm². 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
Before Test After 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.
Figure 18 – Rubbing Test
7. Nichiban Tape 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.
Before Test After Test
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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 1cm² 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:
Figure 21 – cross cut test
9. Mitsubishi pencil Scratch Test
- Propose – To confirm that the scratched surface don’t have any abnormal
condition occur.
- Method – tilting the unsharpened pencil lead (Mitsubishi Uni H) at 45º. 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.
Before Test After Test
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- Remark – in case of operation area by customer shall use H grade. Other area
which customer doesn’t 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 60º for 48 hours. Wipe the tested surface using dry clean
cloth.
- Check point – tested surface must don’t have fingerprint mark appear on the
surface after test.
Figure 23 – Finger print test
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 didn’t meet the S&O Electronic Sdn
After 48 hours in 60º Finger Print before 60º After wipe using dry cloth
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Bhd’s 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 don’t 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
Pre–production 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 pre-
production 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.
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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 doesn’t assembly system. For an
example doesn’t 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:
Figure 26 – Electrical screw driver & Speaker
Screw
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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, mass-
produced 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
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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
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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
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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
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
MARKET SURVEY
NEW PRODUCT PLANNING OUTLINE
ISSUE DRAWING
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STAGE 2: DESIGN INPUT
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
PRODUCT PLANNING / DESIGN CENTER
DESIGN CONCEPT
LAYOUT STUDY
FINALISE PLANNING
OUTLINE
FINAL DRAWING
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• Battery arrangement
• Interference of each major parts
• PWB layout
• Cost estimation
STAGE 3: DESIGN OUTPUT
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
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
“O” JI SAMPLE
“O” JI EVALUATION MEETING
ROUGH SCHEMATIC
DRAWING
O JI PWB
O JI PWB DRAWING
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• 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
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.
NEW MODEL MEETING
OFF TOOL
OFF TOOL DRAWING MEETING
TRANSFER
MATERIAL
MECHANICAL IMPROVEMENT ELECTRICAL IMPROVEMENT
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STAGE 6: DESIGN VERIFICATION
Figure 32 – Stage 6
• Study and improvement base on initial customer’s 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
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.
SOUND QUALITY APPROVAL
CONFIRMATION MEETING FINAL COST
DECISION
PRODUCTION APPROVAL
PER - PRODUCTION
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CHAPTER 5
CONCLUSION AND RECOMMENDATION
5.1 CONCLUSION
Training in S&O gives a huge impact to the trainee’s 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 student’s 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
Figure 36 – Right view
This product defined as world’s 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.
Sound bar
Subwoofer
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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:
Ø 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.
Ø 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.
Ø 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.
Ø 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.
Ø 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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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 it’s 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 trainee’s 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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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. It’s 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 customer’s attention. This is because
customer’s view is important in the business field. By doing research on the
competitor’s product can improve SHARP’s 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. It’s like kind of disturbing to morning meeting. So the HR department must issue
new rules for phone calls.
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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, McGraw-
Hill Companies.Inc, 1989.
3. Ng Teck Leng,’Industrial Training Report’ University Technology Malaysia, 2005
4. GVU’8th WWW user survey. (n.d). Retrieved April 20, 2011, from
http://en.wikipedia.org/wiki/New_product_development
5. GVU’8th WWW user survey. (n.d). Retrieved April 20,2011, from
http://www.witiger.com/marketing/newproductdevelopment.htm
6. GVU’8th WWW user survey. (n.d). Retrieved April 20,2011, from
http://www.slideshare.net/anicalena/new-product-development-process-diagram
7. GVU’8th WWW user survey. (n.d). Retrieved May 14,2011, from
http://192.168.117.152/eng1/index.html
8. GVU’8th 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. Sharp’s 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
I assembly the subwoofer’s power
Amp set
2D drawing using Power Draw
software
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
Aging Test
CORE SIDE OF PWB
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APPROVAL FORM
CHAMBER
