Fyp report free essay sample

First and foremost, I would like to thank to my supervisor from University of Malaya who also act as the Coordinator for Industrial Training for 2011/2012 session, Dr. Farazila Binti Yusof for helping me during the period of my training and Dr Salwa Hanim Binti Abdul Rashid for visiting me during my period of training. They had taken a lot of efforts to come up with helpful guidance and advises while the industrial training process. Secondly, I would like to acknowledge my thanks to Dr. Abdul Hamid Saleh, the Head of Furniture Design Unit in Forest Research Institute Malaysia (FRIM), who is my supervisor at the company during 2 month and 2 weeks of my industrial training. He had assisted and cooperated with me so I can complete the training successfully. Besides, I would like to extent my gratitude to the company, Forest Research Institute Malaysia (FRIM) for their kindness and their trust giving me the chance to have my Industrial Training in there. We will write a custom essay sample on Fyp report or any similar topic specifically for you Do Not WasteYour Time HIRE WRITER Only 13.90 / page I would like to gratitude to Miss Yanti Binti Abdul Kadir, Miss Tuan Anis Nadia Binti Tuan Mohd Saipudin, Mr. Haji Ab Jalil Bin Muhammad and Mr. Sopian Bin Mukhtar, staff in Furniture Design Unit. Without help from them, I surely came into deep problem in completing everything regarding the industrial training process. Finally, I would like to express my heartfelt gratitude to my family, friends and also lectures for their support, constructive suggestions and also critics. Thank you for all. 1 ABSTRACT The student Industrial Training Program involve the placement at UM students in organizations for a specified period of time. It is a part of the degree requirements at the Faculty of Engineering University of Malaya in order for the students to successfully complete their Bachelor of Engineering. The objective of this industrial training is to expose students to the actual working environment. By undergo the industrial training, students will create a trust worthy and responsible person. Besides that objective of industrial training is to build self-confidence among students and let students know the technical knowledge and professionalism. I was placed in Furniture Design Unit (FDU) during my industrial training in Forest Research Institute Malaysia (FRIM). I had learnt on how the process planning were done in producing some products and to design a table for four people where its main materials is from bamboo flat board. This field of works are strongly related with the subjects that I have learned in university, they are Product Design, CAD/CAM and Basic in Manufacturing Process. A few software are used in these departments such as ProEngineering and AutoCAD. In conclusion, my industrial training at FRIM was a satisfactory and enjoyable experience. 2 CHAPTER 1: INTRODUCTION 1. 1 BACKGROUND OF FOREST RESEARCH INSTITUTE MALAYSIA (FRIM) Company Name : Forest Research Institute Malaysia (FRIM) Address Forest Research Institute Malaysia (FRIM), 68100 Kuala : Lumpur, Federal Territory of Kuala Lumpur, Malaysia Telephone : 603-62797000 Facsimile : 603-62731314 Web Site Link : http://www. frim. gov. my 1. 1. 1 Overview The Forest Research Institute Malaysia (FRIM) founded in 1929 as the Forest Research Institute (FRI) was a department under the Forestry Headquarters Peninsular Malaysia. It was not until 1985, the Institute became a statutory body governed by the Malaysian Forestry Research and Development Board (MFRDB) under the then Ministry of Primary Industries. Later in 2004, FRIM was administered by the Ministry of Natural Resources and Environment. Located 16 km north west of Kuala Lumpur, the 544. 3 ha campus is surrounded by the Bukit Lagong Forest Reserve. FRIM, which recently was awarded the MS ISO 9001:2008 accreditation is headed by its Director General, Dato’ Dr. Abd. Latif Mohmod. 3 Figure 1 : Road map of FRIM FRIM promotes sustainable forest management and the optimal use of forest resources through the knowledge and technology generated from the various researches conducted. Not only is FRIM proud of its diverse expertise, its award-winning researches and international collaborations have earned the Institute a name for itself in the tropical forestry. FRIM has five research divisions, three technical support divisions and three administrative and finance divisions. Of the five research divisions, the Forestry Environment Division focuses on conservation of forest ecology and biodiversity by providing data, standards and guidelines in managing tropical forest on a sustainable basis. The Forestry Biotechnology Division researchers into ways to establish cost-effective forest plantations as an alternative and/or supplementary supply of timber. The Forest Products Division researches into the utilization of ligno-cellulosic materials and promotes the development of forest based industries. The Forest Biodiversity Division focuses on the conservation of forest biodiversity by providing samples, data, standards and guidelines in managing the tropical forest, while the Medicinal Plants Division researches into the medicinal values of forest plants and product development. 4 Among the facilities available at FRIM are the five arboreta that serve as ex-situ conservation areas and references for forestry education, a xylarium with more than 10,000 wood samples of over 1,500 species, a herbarium established in 1908 with over 200,000 specimens, a library, a nursery, several venues for seminars and conferences. The nine field stations located in different localities in the country also facilitate researchers conducting studies in respective areas. The Institute also offers a wide range of tests and services for the industries such as preservative test, soil test as well as resistant tests for furniture and fire doors. FRIM, which has become a popular spot for picnickers, joggers and nature groups provides visitors, opportunities for outdoor recreation and nature education activities. It is also a preferred place for family day event, bird watching, jungle trekking and nature photography. The campus, which was once a degraded land with and long-abandoned sterile mining pools, scrubby wasteland and barren vegetable farms, is today a haven for nature lovers to enjoy fresh and for serene ambiance. 1. 1. 2 Mission, Vision and Objective ? Mission To deliver science-based innovations and solutions meeting forestry needs for today and tomorrow. ? Vision By 2020 FRIM will be a world leader in tropical forestry research. 5 ? Objective General Objectives: To generate scientific knowledge for the understanding, management, conservation and use of forest resources To achieve excellence in research and development through the use of the latest scientific equipment To study biodiversity to produce useful products through intensive research and development To develop related technology to fulfill the needs of the forestry industry To package research and development findings for dissemination to clients To commercialize research and development findings through technology transfer to all interested parties To provide excellent service to fulfill client needs To create strategic cooperation with local and international agencies To raise public awareness regarding the importance of the environment and the conservation of forest biodiversity Operational Objectives: To provide human resource development programs to produce a class of authoritative and competent scientists To provide a work environment that is conducive to encourage creative thinking among scientists and a close relationship with clients To disseminate the technological and research products as well as giving accurate and professional advice and technical services To provide practical solutions to problems involving management and usage of forest resources and products To provide facilities and professional services in order to raise environmental awareness. 6 1. 1. 3 Commitment to Quality of FRIM Corporate Quality Policy FRIM is committed to providing effective research and related supporting services to fulfil its Customers’ needs. We ensure that those working with and for us shall be committed and adhered to the quality standards that have been identified. FRIM will carry out continual improvements to enhance the effectiveness of related systems. Operational Quality Policy We are responsible for: conducting research and providing quality professional services appropriate to the customers’ needs and expectations in the tropical forestry and forest product sectors; implementing Quality Management System (QMS) effectively within the scope of research, training, testing calibration, selling, renting and consultancy services, in accordance to MS ISO 9001 requirements; monitoring the effectiveness in the implementation of the QMS through feedback received from customers; ensuring that the continual improvement on the current quality objectives through effective corrective and preventive actions based on the key performance indicator analysis which is done consistently; ensuring that all procedures and services provided to customers are reviewed to meet the standard requirements; ensuring that any failure towards achieving the identified standard is reviewed and evaluated to be used as a reference in the continual improvement process; ensuring that the quality policy is understood by FRIM’s personnel through briefings, meetings and poster exhibitions; 7 To ensure that all personnel implement the policies and procedures in all aspects services provided to the customers. 1. 1. 4 Logo and Motto ? Logo Figure 2 logo of FRIM ? Motto Conserve, Innovate, Educate 8 1. 2 BACKGROUND OF FURNITURE DESIGN UNIT (FDU) Furniture Design Unit (FDU) is a unit under the division of Forest Product in FRIM. The current Head of Department is Dr. Abdul Hamid Bin Saleh. 1. 2. 1 Objective Related Research Process Management To ensure that at least one (1) research project conducted annually Obtaining research funds of RM150000 a year from government and nongovernment funds, from within and outside the country produced four technical and semi-technical paper of the resea rch findings every year, including a journal produce at least one invention disclosure of research activities every year Promotion-Related Process To ensure participation in the promotion of R D through exhibitions, innovation, national and international competitions for at least two entries per year Matters Related to Services Aim for at least one year of professional consulting services Earn at least RM1000 from technical, equipment rental and room service as well as organized training per year Process Related to Training Co-organizing at least one training for the industry. Four students practical from IPTA/S. Two training program in one year from the field of materials technology and design. 9 1. 2. 2 Customer Charter 1. Send at least 90% of the final report RD projects undertaken to sponsor within three months after the project completion 2. provide at least 90% of responses to the consultation questions, technical, consulting and training to customers in the period of time mutually agreed between the customer involved 3. give at least a 90% response to the customer within five working days after receipt of the complaint 10 1. 2. 3 Organization Chart Figure 3 Organization Chart for Furniture Design Unit (FDU) 11 CHAPTER 2: TASK AND ACTIVITIES 2. 1 WEEKLY TASK I was assigned in Furniture Design Unit during this industrial training. During the ten weeks of industrial training, a lot of experiences and exposures have been obtained. Activities and training had been planned and structured well and been illustrated into a schedule. The report show 10 weeks of daily task. DATE/DAY WEEK 1 26/6/2013 28/6/2013 TASK/ACTIVITIES 1. Report at Furniture Design Unit (FDU), Forest Products Division, FRIM. 2. Briefing by Miss Yanti Miss Tuan Anis. Introduction to FRIM and FDU Visit workshops, lab all office regarding to Forest Products Division 3. Report at Human Resource Centre, FRIM. 4. Attended ISO meeting for FDU. Explanation regarding ISO Need to involve in updating file for ISO WEEK 2 1. Update all file before 4/7/2013 as they will be two internal 1/7/2013 auditor as a panel for ISO they will come and check all 5/7/2013 file. 2. Attended ISO audit session. 3. Involved in preparing sample (bamboo, sesenduk jelutong) for the surface roughness quality test. WEEK 3 8/7/2013 12/7/2013 1. Prepare a brochure for the AutoCAD software application workshop. 2. Attended a Safety Briefing by En. Mohd Nasir Mat Arif, 2nd Officer for Safety in FRIM. 12 3. Do some research for criteria in designing moulded chair. 4. Design a moulded chair by using Pro-E software. WEEK 4 1. Attended ISO Management meeting 15/7/2013- 2. Being assigned to : 19/7/2013 Design a bamboo flat board table for four people Make a report of process in the making of bamboo flat board table. 3. Data enty for surface roughness test for bamboo, sesenduk and jelutong. 4. Attended Management Industrial Training Meeting WEEK 5 1. Do some research on FRIM, FDU, FITEC 22/7/2013- 2. Started preparing final Industrial Training Report 26/7/2013 3. Visited FITEC (Furniture Industry Technology Center) 4. Visited National Craft Institute (IKN) WEEK 6 1. Prepare sketches for bamboo flat board table 29/7/2013- 2. Had ‘gotong- royong’ session as a preparation for 5S 2/8/2013 3. Attended surface checking test workshop Learnt on how to use a new devise; microscope for veneer surface checking test 4. Attended Iftar Event for Furniture Design Unit (FDU) which was a compulsory to all practical students 5. Went to Kin Heng Timber Industries Sdn. Bhd. For site visit and board manufacturing of coconut, oil palm and sesenduk veneer from 31/7/2013 until 1/8/2013 6. Attended 5S audit session WEEK 7 1. Continued with final industrial report. 5/8/2013- 2. Prepared for slide presentation for Furniture Design Unit 9/8/2013 (FDU). 13 WEEK 8 12/8/201316/8/2013 1. Re-design the current design as for improving the mechanism involved. 2. Combine improve the concepts of selected design. 3. Drawing final design by using Pro-Engineering software. WEEK 9 1. Attended meeting presentation at FITEC. 19/8/2013- 2. ‘Gotong-royong’ Perdana, FRIM. 23/8/2013 3. Did preparation for the visits from Kolej Kemahiran Teknologi Mara (KKTM) students. 4. Did preparation for faculty supervisor visits on Monday (26/8/2013) 5. Attended Forest Product Division Open House. WEEK 10 1. Attended Furniture Design Unit Open House. 26/8/2013- 2. Meeting and presentation with faculty supervisor and 30/8/2013 industrial supervisor. 3. Attended 5S internal audit session. 4. Submit industrial training report. Table 1 Tasks and Activities 14 2. 2 PROJECT(s) 2. 2. 1 Design table from bamboo flat board Product Description Table top made of bamboo, a strong and flexible material. Small dimensions make the table easy to furnish with, even when space is limited. The table easily adjusts for 2-4 people. The design is kept simple in order to avoid increasing in manufacturing cost. Project Boundaries ? Extendable ? Material used must be light in weight ? Size must be small for space saving ? Stylish outlook ? Modern yet simple ? Ease of use ? Well management of quality control Assumptions Competitive price Light in weight extendable good quality long lasting affordable simple 15 Sketches Figure 4 Ideation and concept development 16 Final Design Extendable table Modern table stand Multi- purpose storage Figure 5 final sketching design 17 Figure 6 Final design for bamboo flat board 18 2. 2. 2 Process flow of bamboo veneer flat board Objective To produce flat board from bamboo veneer same as plywood. Manufacturing of Bamboo Veneer Board (MBVB) SELECTION OF VENEER GLUE SPREADER FLAT PRESS PROCESS CUT AND TRIM TESTING Figure 7 shows the process flow of developing flat board from veneer. 19 bamboo Explanation on each steps of manufacturing (MLBV) Board Step 1: Selection of veneer The good quality veneers are chosen while the ones with defects are selected out and cut to smaller sizes which are then joint into regular size. Check the moisture content (MC) to ensure that it below 12%. This MC will affect the strength of board at the end. If high MC in board it will corrupt the bonding between fiber and adhesive. The pre-produced veneers have the size of 685. 8 mm x 685. 8 mm x 0. 7 mm (length x width x thickness) and the veneers are cut bigger than the dimensions required which is 609. 6 mm x 609. 6 mm as to provide the tolerance for cutting and trimming. The veneers are cut parallel to the grain. Then, the thickness of each veneer is measured using the digital caliper. Step 2: Glue application The type of adhesive used is urea-formaldehyde (UF). The advantage of UF glues is it does not introduce any moisture to the veneer as there are chemical curing process involved. In addition, the UF glues has longer open time, waterproof, heatproof and dries as crystalline. We used glue spreader to the bamboo veneers selected so that the adhesive is applied evenly on both side of veneers surface and arranged them together into a form of a board. As for ply-type board, the veneers are arranged perpendicular to each layer until it reached the desired thickness according to the type of boards to be produced. There are 2 different types of bamboo boards produced which are 100% bamboo board and hybrid board. The specifications of each type is: Type of Thickness boards (Â ± 1 mm) 100% bamboo 7 Hybrid Bamboo 9 12 Number of bamboo veneers Number of wood used veneers used 10 plies 13 plies 6 plies 7 plies Table 2 shows the specifications of each type of boards 20 Before applying glue, the veneers are weighed individually and the mean weight is calculated. Then, each bamboo veneer is inserted into the glue spreader and the glued veneers are then weighed again. A type of plastic is used to avoid the glued veneers from sticking to the balance. Figure 8 Weighing before and after gluing For the production of 100% bamboo, plies of glued veneers are arranged together and the total weight of the compiled veneers is taken. Bamboo veneers Figure 9 shows the arrangement of 100% Bamboo Board 21 While for the production of the hybrid board, it consists of two different veneers which is bamboo veneers and wood veneers. Firstly, 3 plies of glued veneers are compiled to produce a 2. 1 mm thick bamboo board. One hybrid board required two bamboo board to serve as the top and bottom layer of the hybrid board. Each of the bamboo board is weighed. In between the bamboo boards is the 1. 2 mm thick wood veneers; glued, arranged perpendicularly and compiled with the bamboo boards to form a hybrid board. Seven plies of wood veneers is used per hybrid board. Finally, the total weight of the hybrid board is taken. Top Bamboo Board Wood veneers Bottom Bamboo Board Figure 10 shows the arrangement of Hybrid Board 22 Figure 11 Glue being spread on the veneer using glue spreader machine Step 3: Flat Press Process After being compiled perpendicularly ply by ply, the veneers are pressed in hot press machine, Burkle, with the temperature of 65 ? C for 8 minutes. The pressure given is 12 x 106 N/mm2. The purpose of pressing is to cure the adhesive so that each veneers are strongly bonded to each other. Hence, a strong flat solid board is produced. The thickness of the board produced is measured using the digital calliper. 23 Figure 12 Pressing the arranged veneers using flat press machine Figure 13 Bamboo boards produced after pressed 24 Step 4: Cut and Trim The boards produced are cut into exactly 609. 6 mm x 609. 6 mm (2 ft x 2 ft) and the edges are trimmed for the purpose of tidiness and to improve the appearance. The tools used for cutting the boards are cutter and table saw. Figure 14 Cutting the board into size using table saw Step 5: Testing The tests are divided into 2 which are physical test and mechanical test. Physical Tests Mechanical Tests 1. Thickness swelling and 1. Bending test water absorption 2. Shear test 2. Density and moisture content test Table 3 shows the type of test for each division Before the test, the board needed to be cut into sample sizes. The cutting pattern is drawn on the board and then the testing samples are cut into dimension of 250 mm x 50 mm for bending test and 125 mm x 25 mm for shear test using the arm saw machine. The samples are left in the room condition of 20 ? C temperature and 65% humidity for 4 days until they reach equilibrium moisture content. 25 12 mm 12 mm mm mm 250 mm 125 mm (a) (b) Figure 15 shows the testing samples dimensions. (a) Bending test (b) Shear test Moisture Content Bending Test Shear Test Figure 16 shows the cutting pattern of the samples 26 Figure 17 shows Physical test – Thickness swelling and water absorption Figure 18 shows Mechanical test Bending test and shear test 27 2. 3 VISIT(S) 2. 3. 1 National Craft Institute/ Institut Kraf Negara (IKN) (25/7/2013) Top: (left) photo shoot session between FRIM IKN Staffs, (right) third year student shows us his hand skills on carving shoe rack. Bottom: (left) all third year students with their hand skills on carving shoe rack, (right) third year students’ work of carving shoe rack. 28 2. 3. 2 Kin Heng Timber Industrial Sdn. Bhd. Chemor, Perak (31/7/2013-1/8/2013) Top: (left) Photo shoot session between Industrial Supervisor, Dr. Abdul Hamid Saleh with practical students, (right) Short briefing by Dr. Abdul Hamid Saleh before entering the factory. Bottom: (left) Student with sample of bamboo veneer, (right) some of product produced at Kin Heng Timber Industries Sdn. Bhd. 29 2. 4 OTHER ACTIVITIES 2. 4. 1 Surface Checking Test Workshop (30/7/2013) I have attended Surface Checking Test Workshop regarding the usage of laboratory device which is Dino-Lite Portable Digital Microscope. The microscope is used in surface checking test for veneer and it has an advantages of the ability to zoom in up to 200 times enlargement and the usage of the device and the software is simple and user friendly. Dino-Lite Portable Digital Microscope. 2. 4. 2 Weekly Meeting Attended management meeting with all staff in Furniture Design Unit (FDU 30 2. 4. 3 Gotong-royong for 5S Gotong-royong Perdana FRIM (22/8/201323/8/2013) Left: Clean up front sites of Furniture Design Unit (FDU). Right: Peeler machine that has been cleaned up. 2. 4. 4 Update file for ISO (1/7/2013-3/7/2013) Before After 31 2. 4. 5 Involved in preparing sample for surface roughness and surface quality test for Bamboo, Sesenduk and Jelutong veneer. (5/7/2013) Left: Cutting and trimming bamboo veneer. Right: Sample of bamboo veneer. 2. 4. 6 Meeting presentation at FITEC (21/8/2013) Left: Attended meeting between all staff of FDU together with FITEC staff. Right: Presentation of the console table, chair, coffee table, dining table and book shelf design by Industrial Design student. 32 CHAPTER 3: DISCUSSION AND RECOMMENDATIONS Internship program is a great chance for trainee to the working environment and prepared themselves for their final year projects. Otherwise trainee will have better understanding on engineering field and practice them on how to handle projects and how to solve the problems with their knowledge. It is not hard for me to understand about environment of this company because the company is based on designing and research and development and I had learnt about CAD/CAM during my 1st and 2nd year of study in university. But, I need a few times to understand about the research that are involved in this company as they are more on research and development regarding forest materials which is not in my course. When it comes to production system, many new things I had learnt in there. Before this I just learn a basic on production planning during my 3rd year of study. But, during this industrial training, I learnt about production planning deeper, starts from how the production line starts, until it finish. In addition, some recommendations from my side are the students who are really interested in doing their industrial training in Furniture Design Unit (FDU), FRIM should have interest in designing furniture from forest material and involve in production process. Subjects like CAD/CAM and Basic in Manufacturing Process are strongly related with this company’s system and for those who willing to make their industrial training in this company should emphasize more on that subjects. Finally, the students who are doing the industrial training should have passion to learn new things. It is because the working industry is a huge field of knowledge and it is impossible for us to study the whole things in class during our university time. Therefore, we should prepare on our own to face the situations and adapt with the environment, and learn as much as we can 33 CHAPTER 4 CONCLUSION Industrial Training program was one of important component in co-curriculum program that can be practice in university. This program was for students to improve the knowledge, technical skill and also able to deal with the so-called real life working environment. All the experiences and lessons learned throughout the training duration are very precious and invaluable. I manage to feel the position of designer and production engineer of the company, and I believe to become a designer and production engineer for a company is a big responsibility because the production of the company is based on your design and the process flow is based on the production planning. In conclusion, I would like to say that the industrial training objectives in this company are achieved.