Bab 1 Introduction

Industrial training report

CHAPTER 1INTRODUCTION

1.1) Introduction Of Industrial Training

Industry Training is a key subject in the curriculum of learning at thePolytechnic Ministry of Higher Education Malaysia is required for eachsemester four courses . Diploma in Mechatronics Engineering (DEM ) are requiredto pass all semester for industrial training. Students must pass the industrial trainingin order to continue their studies after the training industry without any failure andrecommended for award of a certificate or diploma polytechnic. If students fail intheir industrial training, students are required to repeat , again until graduation tomeet the academic requirements .

Students will be placed in government or private firms for a semester to expose them to the working environment that is different from the atmosphere at thePolytechnic . Students are given the freedom to choose where to go for industrialtraining either in the government or private firms with all students encouraged toapply personally or through the Polytechnic . Training should be applied inaccordance with their field of study at the Polytechnic . This is important so that the


industrial training is carried out at a place in accordance with the requirements of thePolytechnic students and to determine the training objectives fully .

Students are encouraged to practice and apply what they learned during theirstudies at the Polytechnic in order to be used in industrial training. The training alsoaims to expose the students to the organizational structure of the department or firmin training so that students understand the work ethic of an organization or firm andexpect students to adapt to the working environment. The training core opportunityfor students to find jobs after graduation. Thus , the Industrial Training is very useful for students who will be undergoing the workforce after they complete their studies at university or college with courses they have taken.All students who undergoing Diploma In Mechatronics Engineering ( DEM)were reminded that Industrial Training in Industry ( 5 months) is compulsory as partof the requirement for graduation . Student who did not go for industrial training will not be able to graduate from the Diplome Programme .Students were required to participate and work as industrial trainees in theindustry of their chosen discipline . Industrial training provides the opportunity forstudent to comprehend and and appreciate provides real life working experiencegained during the industrial training . The attrachment provides students to meet and network with people in the industry , and identify talents and potential skilledworkers . Students may also get the opportunity to specialize in niche areas . Industrial training report

1.2) Objective Of Industrial Training

During undergo industrial training; the students are given an opportunity to learn about working environment. Besides that, they also are given doing works or assignment that closely related to their course or directly practical through from the company.

This is because of working environment are definitely different with all the theory that been studied at polytechnic. All student also got opportunity to be trained in the real working environment about discipline, teamwork, communication skills and punctuality where it immensely useful of student in the future.Through this practice, theres a lot of experiences and knowledge that every students gained. Of course our polytechnic hopes that the objective of this practical can be achieved by each of the students in order to make sure every student get an excellent success in their industrial training. The main objective for industrial training such as:. To prepare students for employment at the conclusion of their studies by providing an opportunity to relate academic and practical aspects of their work .. To acquaint students with first hand knowledge of the various aspects of works as they really are in industry.. To provide students with opportunity to apply their educational experience and knowledge in industry.

Industrial training report. To provide students with opportunity to establish contact with the profession of their choice , hoping that this may lead to employment after their graduation .. To provide the industry an opportunity to assess performance of its potential employess . To discover , learn about , and familiarize with the industry of their discipline , and with organisation within the industry .. To observe real life practices and implementation of theoretical lessons and principles .. To acquire practical skills and experiences working on projects and meeting with professionals in their field of study . . To evaluate the company they might wish to work future .. To let all the student uncover at the real working field . . To increase or expand the technical knowledge to students from industrial training .. To introduce our self by ability and willingness for company . . To allow the entire students makes a comparison between the theory and skill from industrial training .

Industrial training report. To cultivation a team work and good relation between student and staff at company . . To raise a consciousness and improve the interest for all student from industrial training .. Give experience to students for the future working environment .. To practice the entire students about the rules and safety skills from industrial training .. To increase a spirit of trust , dedication and responsible every students from industrial training .. To strengthen the confidence and determination every students .

1.3)Objective Of Report Industrial Training

The preparation of this industrial training report carried out in order to enable student achieved their certificate or diploma which is follow courses offered in Sultan Azlan Shah Polytechnic. The purpose of this industrial training report is to documentation all activities during training. For example such as record each work done by student or what they saw from the firm staff. Every work which is given by firm staff should be jot down in the report. This report also can be used as a reference by students. All students will be judge by their industrial training report.


Objective for report industrial training is a one of the important document due to:i)To documentation all activities during the training period.ii)To be a proof for all students to make sure they follow the job that giving by company.iii)The good and valuable report can be use for interview when they finished study at polytechnic. 1.4)Important Of Industrial Training For StudentIndustrial training is important thing for student either student from certificate courses neither student from diploma courses. With the experience in work environment, it will helped student for seeking work after accredited certificate or diploma in Polytechnic. It was important because it will produce attitude student, discipline student and punctual student. Student also can learn now things during their training. Industrial training is a condition for every student was undergoing any course in polytechnic before last semester:To exposed student at the working environment.To improve technical skills of the student.To make student follow superior instruction.To improve student more confident in working field.

Industrial training report 1.5) Scope Of Industrial Training The scope of industrial training was I get from this company is made up of various field. It will to be some of a field to let student more understand and can follow the request from company. There are a lot of skills or knowledge already learnt by me from industrial training. I can learn about the method of calibrated the instrument, method of control the environment and method of checking the ESD by using the standard instrument. Besides that, I also learnt how to working at real working life when I was starts my working at one company after I was finished studying.


CHAPTER 2 COMPANY BACKGROUND

2.1)Introduction Of Company

UNISEM (M) BERHAD , which is located at kawasan Perindustrian Pulai Jaya near Ipoh . UNISEM (M) BERHAD is a leading semiconductor packaging and test services company in Malaysia, has its main packaging and test facilities in Ipoh, Malaysia. UNISEM offers an integrated suite of packaging and test services for semiconductor companies such as wafer bump, wafer probe, wafer grinding, a wide range of lead frame and substrate IC packaging, high-end radio frequency and mix-signal test, tape & reel and drop-shipment services.


With approximately 5,000 employees worldwide currently, UNISEM has more than one million square feet of IC packaging and testing manufacturing space in Ipoh, Malaysia, Wales, United Kingdom and Chengdu, Peoples Republic of China and 20,000 square feet of wafer bumping facility in Ipoh, Malaysia.

UNISEM has a customer base comprising primarily fables companies and to a lesser extent design houses and a small proportion of integrated device manufacturers. About 83% of UNISEM sales are to customers in North America, 11% to Europe and 6% to Asia.

UNISEM has the capability of packaging and testing a wide range of lead frame package, which are expected to remain as the most cost-effective solution for applications under 100 leads. Driven by customers demand, UNISEM is looking into developing advanced lead frame packages, such Chip Scale Package (CSP) and Flip Chip. Industrial training report

2.2) Logo And Company Address

Figure 2.1: Logo of UNISEM (M) BERHAD

Address : UNISEM (M) BERHAD NO 1 PERSIARAN PULAI JAYA 9 KAWASAN PERINDUSTRIAN PULAI JAYA 31300 IPOH PERAKTelephone Number : 05-3572800Fax Number : 05-3572100


2.3 )Vision

To be a leading global multinational company providing comprehensive turnkey assembly and test services for the evolving needs of our customers, and a model corporate citizen in the communities in which we operate.

2.4) Mission

In order to achieve our vision, UNISEM are committed to: Provide total customer satisfaction. Be a caring company and employer or choice. Generate profits and accelerate growth. Develop long-term Win-Win partnership with our business associate. Adhere to good corporate governance and support environmental, social and economical development of the community. Up hold and live our core values.2.5) Core ValuesUNISEMs core values are: Teamwork: We value our differences and synergize to fulfill company goals and the stakeholder's requirements. Industrial training report

We hold responsibility and accountability for all tasks assigned to us. We practice empathic communication between all parties. We recognize that the foundation of a great team is mutual trust of team members.

Commitment: We involve ourselves in decision making. We have the courage to make promises and keep it. We take initiatives to seek knowledge and pursue our goals aggressively. We are passionate and focused in what we do. Trust: We show high consistency between words and deeds in our dealings with peoples. We are committed to conduct our business with a high standard of ethics and integrity. We trust our people and recognize their intrinsic desire to do a good job. We engage in open, constructive, ideological debate. We treat each other with respect and dignity. Proactive: We encourage creativity and innovation in our work. We promote a learning culture so we can continuously upgrade our skills and process capabilities to adapt to new dynamic business environment. We plan ahead in anticipation of new challenges and opportunities. We do not react to changes, we initiate changes. Industrial training report

We take calculated risks. We believe that it is far better to try and fail than not trying at all.

Caring: We practice a culture of safe, clean and green. We recognize our social obligations to our stakeholders and the society and we contribute positively to our communities and environment. We recognize our human resources as our greatest asset. We reward our people fairly. We practice 7 Habits daily.

2.6)Environment Policy

In line with corporate vision to be and be recognized as the finest semiconductor packaging services company of choice, it is UNISEM management policy to show exemplary environment responsibilities by conducting our businesses in a manner consistent with sound environmental practices. To achieve this, UNISEM will ensure that their conduct and operations are in accordance with the principles and guidelines contained in this policy.


It is the policy to: Identify and carry out continual improvement on machine, processes and surroundings in order to meet environmental management system requirement. Practice good housekeeping and chemical storage methods to minimized potential impact on the environment. Comply with legal requirement and EMS specification. Promote energy saving and the conservation of natural resources. Identify and promote the reuse and recycling of resources and reducing the use of hazardous substances. Establish an emergency response plan to handle occurrences of potential emergency situation. Encourages means to reduce pollutants to the air, water and land as well as preventing potential negative impact on the environment. Promote environmental awareness to the employees with proper training and publicity. Encourage our suppliers and contractors participation to meet our EMS requirement. Provide environmental policy to the public upon formal request.

The management will conduct periodic review of this policy and monitor the progress of the environmental management programmed to ensure the compliance of this policy.


2.7)Safety And Health Policy

UNISEM (M) BERHAD places great importance on the welfare, health and safety of our employees. UNISEM regard their employees as our most valued asset and it is their policy to promote high safety and health standards in order to provide a safe and healthy working environment for employees and the public. UNISEM will conduct work and maintain our workplace in a manner, which is consistent with the principles and guidelines shown in this policy.It is the policy to: Promote a conductive environment for persons at work, which is adapted to their physiological and psychological needs. Promote continual improvement on the standards on the standards of safety and health. Confirm to statutory requirement, codes, guidelines and standard for occupational health and safety and liaise with all responsible authorities concerning future development. Inform, instruct and train all employees to help them develop an understanding of the workplace, its hazards, and the need to work within established practices. Consult with employees on health and safety hazards, and once identified, on their rectification. Advise visitors to the Company premises of any safety precaution, which are necessary in the areas they are entering and inform them that they will have to comply with these requirements. Industrial training report

Recognize the companys obligation to consumers and the public by endeavoring a tall times to provide products, which are safe, if properly used for the purpose for which they were made. Implement and maintain systems for the management of all major aspects of occupational health and safety, including accident reporting, recording and measurement against objectives.

This is achieved through periodic review of safety and health system by the management in connection with the operation, handling, storage and transportation procedures relating to all employees.

2.8)Quality Policy It is the policy to: Produce products and provide services of the highest quality as perceived by each and every customer. Commit to on-time delivery and to be the most cost effective assembly house.This is achieved through a precisely designed and well defined system of manufacturing excellence and concerted strength of people involvement. Ultimate goal is an absolute and continuous TOTAL CUSTOMER SATISFACTION.


2.9)Quality Assurance

In line with Quality Policy, Reliability & Quality Assurance Organization is structured to ensure that the established quality system is structured to ensure that the established quality system is being implemented and maintained, as well as to ensure services provided and finished products built per customers requirements.

From incoming materials to final test, packaging and shipping, quality is assured along the manufacturing process through the usage of Quality Control Plan and Statistical Process Control monitoring. The control plan covers the prototype build, pre-production build and mass production to control all critical parameters and special characters of the products along the manufacturing process.

In UNISEM, methods of verification for acceptance may include one or more of the following: Visual Inspection Line Functional Test Certificate of Conformance (C of C) Certificate of Chemical / Spectrographic Analysis Tests and/or Inspection Reports Statistical Process Control (SPC) Data Supplier Plant Manufacturing Process Audit


2.10)Plant Dimensions Overview Figure 2.2: UNISEM OverviewOver the years UNISEM has invested approximately RM820 million in land, building, plant and machineries. Operating from its factories (Phase I, II and III) in PULAI JAYA, IPOH, and UNISEM has a current staff total of 2600. The factories, with a total built up area of about 570,000 square feet, are erect on a 15-acre site.

2.11)Local And International Market

All of UNISEMs product are exported. About 65% of UNISEMs sales are directly exported to customers in North America, Asia and Europe, with the balance exported to multinational corporations located at various Free Trade/Industrial Zones in Malaysia. With a sound balance sheet, UNISEM will strive and adapt to support its customers as they expand and grow.


2.12)Portfolio

UNISEM manufactured numerous packaging capabilities including various pin counts of PDIP, SOIC, PLCC, QSOP, SSOP, MSOP, TSSOP, SOT, SC70, TO, MICRO-X, MICRO-P and SLP (QFN) with TQFP and BGA coming into UNISEM package product portfolio. The full name for each of the package was shown below: BGA (Ball Grid Array Package) DFA (Dual Flat No-Lead Plastic Package) PDIP (Plastic Dual In-Line Package) SOIC (Small Out-Line Integrated Circuit) PLCC (Plastic Leaded Chip Carrier) QSOP (Quad Small Out-Line Package) SSOP (Shrink Small Out-Line Package) MSOP (Mint Small Out-Line Package) TSSOP (Thin Shrink Small Out-Line Package) SOT (Small Out-Line Package) TSOT (Thin Small Outline Transistor Plastic Package) SC (Small Circuit) Industrial training report

MICRO X MICRO -P (Micro Plastic) SLP (Small Leadless Package) 2.13)Plant Overview (FOL 3 Iso14001)Figure 2.3: Photo of part inside the FOL (ISO14001).

UNISEM offers a comprehensive range of assembly and test capabilities. Its equipment standardization for major operations included ESEC for die attach and wire bond operations, HANMI auto molding system, HANMI and ASM trim/form, and CEM auto strip-to-strip plating line for the front-of-line clean room.

UNISEM continually increases its manufacturing capabilities by adding state-of-the-art equipment, including 8 inch wafer processing and fine pitch wire bonding of 80 micron and below. All the above are house in one of the cleanest working environments in the world. UNISEM facilitated 5k front-of-line clean room, which exceeds the standard required in the industry. In keeping with world environmental standards, the manufacturing processes use only non-ozone depleting chemicals. The facility employs an air scrubbing system and has its own waste water treatment plant. Industrial training report

The clean room has an Environmental Policy that is committed to legal compliance, pollution prevention/reduction and continual improvement.

2.14)Organization Structure Figure2.4: UNISEM Organization

2.15)Managements of UNISEM (M) BERHAD

2.15.1Service Offered In UnisemTEST ENGINEERING1) Test development

Main test platform: TMT, EAGLE, LTX Industrial training report

Test program transfer between different platforms Test program debugging and optimization Test program and hardware development

2) Product Engineering

Test program control New device correction and qualification Product failure analysis Yield and quality improvement Low yield verification and analysis

3) Equipment engineering

Tester and handler communication interface Calibration and repair of all equipment Set-up and buyoff of new testers and handlers Equipment performance monitoring and improvement

2.15.2)Total Productive Maintenance (TPM)

Total Productive Maintenance (TPM) is productive maintenance carried out by all employees through small group activity. TPM aims at maximizing production system efficiency by addressing the entire equipment life cycle and building a Industrial training report

concrete, shop floor based system to prevent all losses. Its most significant contribution is the reduction and elimination of the 8 big losses.

Preventative maintenance (PM) procedures had been in place for some time and PM was practiced in most plants. Using PM techniques, maintenance schedules designed to keep machines operational were developed. However, this technique often resulted in machines being over-serviced in an attempt to improve production. The thought was often "if a little oil is good, a lot should be better." Manufacturer's maintenance schedules had to be followed to the letter with little thought as to the realistic requirements of the machine. There was little or no involvement of the machine operator in the maintenance program and maintenance personnel had little training beyond what was contained in often-inadequate maintenance manuals.

The need to go further than just scheduling maintenance in accordance with manufacturer's recommendations as a method of improving productivity and product quality was quickly recognized by those companies who were committed to the TQM programs. To solve this problem and still adhere to the TQM concepts, modifications were made to the original TQM concepts. These modifications elevated maintenance to the status of being an integral part of the overall quality program. Ultimately, UNISEM wants to achieve: Zero Operational Losses Zero Equipment Breakdowns Zero Accidents Zero Adjustments Industrial training report

Zero Rejects/Defects Plant wide Commitment

2.15.3) 5S PILLARS

The five pillars are defined, with their Japanese words as SEIRI (Sort), SEITON (Set in Order), SEISO (Shine), SEIKETSU (Standardize) and SHITSEKU (Sustain). Since these words begin with S, they are also referred to as 5S.

In any company, thorough implementation of the five pillars is the starting point for improvement activities that will ensure survival. This is because, in the daily work of a factory, just as in our daily lives, company perform routines that Sort, Set in Order, and Shine; these are essential to a smooth and efficient flow of activities.

Benefits of 5S Implementation:

Zero Changeovers Bring Product Diversification Zero Defects Bring Higher Quality Zero Waste Brings Lower Costs Zero Delays Bring Reliable Deliveries Zero Injuries Promote Safety Industrial training report

Zero Breakdowns Bring Better Equipment Availability Zero Complaints Bring Greater Confidence and Trust Zero Red Ink Brings Corporate Growth 5S Descriptions:

i. First Pillar - SEIRE(Sort)

SEIRI means that you remove all items from the workplace that are not needed for current production (or clerical) operations. If you Sort, you leave only the bare essentials; when in doubt, throw it out. When the first pillar is well implemented, problems and annoyances in the workflow are reduced, communication between workers is improved, product quality is increased, and productivity is enhanced.

ii. Second Pillar SEITON (Set In Order)

SEITON means that you arrange and label needed items so that they are easy to use, find and put them away. This is important because it eliminates many types of waste in production and clerical activities. The SEITON pillar is the core of standardization. Visual controls are devices used to communicate the standards for how work should be done.


iii. Third Pillar SEISO (Shine)

SEISO means keeping everything swept and cleans to create a clean and bright workplace. The key purpose is to keep everything in top condition so that when someone needs to use something, it is ready to be used. If this pillar is not well implemented, problems arise include poor employee morale, safety hazards, equipment breakdowns, and increase of product defects. Cleaning means inspection. When clean an area, it is inevitable that do some inspection of machinery, equipment and work conditions. The company uses all of our senses to detect abnormalities. Two of the tools used in implementing cleaning / inspection are Cleaning/Inspection Checklists and Checklists of Needed Maintenance Activities.

iv. Fourth Pillar SEIKETSU (Standardize)

SEIKETSU is the result of properly maintaining the first three pillars SEIRI, SEITON and SEISO. The basic purpose of SEIKETSU is to prevent setbacks in the first three pillars, to make them a daily habit, and to make sure they are maintained in their fully implemented state. Some of the tools used are: 5S Job Cycle Charts, Visual 5S, Five-Minute 5S, a Standardization Level Checklist, and 5S Checklists for Factories. Industrial training report

v. Fifth Pillar SHITSUKE (Sustain)

SHITSUKE means to make a habit of properly maintaining correct procedures over time. Usually you commit yourself to sustain a particular course of action because the rewards for keeping to the course of action are greater than the rewards for departing from it.

Industrial training reportCHAPTER 3Summary of daily activityActivities Every Week At CompanyThere are 5 months was I have a industrial training in Unisem (M) Berhad at QRA Department. It let me know about the skills to calibrate the instruments. Furthermore, I also can know how to control the environment insides the line by follow control limits.All the knowledge was I learnt from industrial training is very important and valuable for me.Summary of daily report Week 1 2.12.2013-6.12.2014. Reporting day for Industrial training at Unisem .. Learn how to measure the pressure and the temperature at the machine MUHIBAUER.. Make sure the pressure and the temperature is correct and same like the manual that was prepared .. How to measure carrier tape by using Peel Back Force Tester . Take the goods for the Receive Department.


Week 2 9.12.2013-13.12.2013

. Learn how to put the document in the Qual Report.

. Learn how to put a tape to a reel .

. Measure the pressure and the temperature at the machine MUHIBAUER which is Ds 1500.

.Learn how to take the picture die cheating by using computer.

.Learn how to use the machine MUHIBAUER which is Ds 1500.

Week 316.12.2013-20.12.2013

. Learn how to removal the blade removal for the machine .

.Take the picture die wall by using computer.

. Learn how to marking wafer by using laser machine .

. Put all the document about measuring laser marking inside the Microsoft Excel .

. Measure the pressure and the temperature at the machine MUHIBAUER

Week 4 23.12.2013-24.12.2013.Throw the scarp wafer in to scarp bin.

.Learn how to use BSP ( LC Tape Lamination).


Week 530.1.2013-3.1.2014

.Learn how to use Fully Automatic Laser Saw for laser saw.

.Learn how to use Post Cure Peel Test Procedure.

. Measure the pressure and the temperature at the machine MUHIBAUER.

Week 66.1.2014-10.1.2013. Arrange the document .

.Learn how to use the Part Counter


. Learn how to use the Backside Lamination machine.

. Use laser marking machine to marking wafer .

Week 7 13.1.2014-16.1.2014. Learn how to operation back the wafer in machine MUHIBAUER when the machine was stop .

. Learn how to change the spacer to another spacer .


. Put all the document inside the Qual Report .

Week 8 21.1.2014-24.1.2014. Make sure the die dont have the stick insception .



.Take the picture die wall by using computer.

.Change the spacer 5mm to spacer 3.5mm .

Week 927.1.2014-29.1.2014 . Learn how to use Backside lamination machine without the robotic .


.Learn how to sticking the membrane in a ring by using the machine.

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Bab 1 Introduction