Internship-Week 12:Tuesday-Friday

Well, it proves resentment do run deep as the technician decided to settle an old score with a leaking grease dispenser by effectively using 2 assembly machine that are not running today. In general, when a grease dispenser is assigned to an assembly machine it is for life (in this case until it wears out), this is where the first attempt went to determine whether the problem is located on the assembly machine or the dispenser itself. Hence, the grease dispenser is quickly cleaned out and relocated to a vacant assembly machine, guess what ? *drip drip*. Second attempt, the top portion of the dispenser is replaced entirely, swapping it with another not in service dispenser and operate it on the same assembly machine yet the problem persisted. Well, three times the charm, the successful attempt comes from replacing the entire lower section. Further inspection ends up with the conclusion that the that are gaps where the gears operate due to mechanical wear, the difference is so little but a gap means a leak.

As I was summing it up for the week to get my last signature, another interesting phenomena occurs. Under hues and cries, I finally spotted the spectacle of a dedicated worker. Well, no strings attached, a worker is actually hoisted up with the ceiling crane which is usually used to hoist mould in and out from the double injection unit. No surprise there since a mould easily weighs more than a 100kg. From that height, it is certainly no task for someone with height phobia aka vertigo although his task is just simply to carry out maintenance on the rail which the ceiling crane operates.

Finally, the finale of them all, I was caught by surprised the last few comments that my supervisor left me with to chew on, it's surprising hard to digest. The point is, the so-called assignment which he blurted out somewhere during our initial encounter and conversation, was conveniently never mentioned again in later days. Conveniently as well, he is resigning to operate his business somewhere in Sunway, he was saying he don't have time (actually not bothered) but is is my fault that I can't accomplished my assignment when he himself can't even handled it during his 1-2 years tenure. That he rattles on, doing overtime is commitment and should not get paid (I like to see him do that, usually he's the one going back 5pm sharp), the last blow when he told me for the first time what he want to see in the report, yeah, that's great tell the person when the time expires up.

It took me some time, but I decide to be honest, so if you are reading this, Mr. Adlan, this is the final blog piece and I am going to deliver me logbook under your office door. I am sorry that I lost your contact number, resulting to communicate with emails.

Internship-Week 12:Monday

As the end is coming near, I begin preparing in earnest of the report that is due to come. Well, since camera is practically forbidden (exception cameras on phone for personal usage), so my greatest resource come from none under than the company website. Basically, I need quite a lot of material for my report and presentation. It is kinda sad to find it a under-maintained, little bit outdated with a lot section under construction, at least there are still plenty of assorted information around. The section I took particular interest is the company's history but sadly too are only several statements available.

At the same time, I planned to do a tribute for my fellow coworkers with a short movie clip, alas I hope there are enough time to collect all the pictures I need for the project in mind.

Internship-Week 11:Friday

Usually, the climax occurs when a movie is typically reaches the end and that is exactly what happened today. The latest customer complaint came in, thankfully this time the amount is so much lesser than the previous one but I doubt the effect is greater rather than less. After listening in to grasp the situation, the technicians mutually shared a general opinion that the operators in charge of undertaking inspection of the product is not to be put under too much blame. This is due to the fact when the customer tried to insert it onto a metal rod, the product stuck halfway and checks reveal using camera flashes that the hollow area was blocked. Personally, my untrained eyes under the light can't even see that far inwards yet how better is expected of a trained pair of eyes? Regardless, the person in charge of all the operators decided its about time to gather everybody around for some serious talk. A test is also handed out on that day to gauge inspection personnel capability which requires them to sketch and explain the NG stated. In order not to disturb the mood, I didn't manage to get a snap on the exam papers.

The picture belows depicts the full assembly of inspection's operators as the day shift were about to leave and the night shift checking in, considering the bus doesn't wait for latecomers, it is considerable shorter version of the afternoon scene.

Internship-Week 11:Thursday

When you thought things won't get any worse, as you planned to sit out your remaining time at the company like a pensioner, it just did. Middle inspection couldn't choose a better timing as the section announces a low height error detected on a particular assembly machine but kept to themselves for some time. So, havoc breaks loose with almost every available personnel pull off to do jigging (manual height inspection) and even my fellow coworkers from night shift are roped in earlier to assist. Predictable, blames shifted as the technician understandably can't attempt much at this point since they are not made aware at that time. Therefore, it also becomes harder to locate the root of the problem and rectify it.

Luckily, my days sweeten up by meeting with my visiting lecturer, Dr. Adlan Shah. A charming young man, he inquire about my daily task and role in the department, taking notes, he also tries to ascertain how well informed I am on my company's background and operation. After that, I kept the tour at HBD brief since Mr. Adlan seems to be in a hurry as well. He asked some questions along the way which I am confident that I provided very satisfactory replies. I gave a general outlook for the hybrid damper and all the manufacturing processes associated. Then, he took his leave as I tried to help amidst the crisis.

Internship-Week 11:Wednesday

Another bleak outlook for a day, a big customer complaint dropped in like a bombshell, well I am not so sure about the customer's company size but the amount of NG detected is certainly big. Though I am not in the manufacturing line but I can tell it is a serious blow to the company's reputation especially a lot higher ups subsequently turned up at the assembly area. Later checks will reveal that the product originates from the production period of between March to May. So, the next course of action that the assembly supervisor take is to sort out all past assembly machine settings which includes the bulk I contributed from April to May. The documents are needed to respond to the customer's complaint, by checking for discrepancies can only the error be located. I am quite sure if the error can't be located it will affect future dealings with the corresponding company.

At the bottom is a sample picture of a customer complaint on a future date (didn't remember to take one on that particular day) and a closer up version of it which there is a red box highlighting the location the NG is detected.

Internship-Week 10:Thursday

After a bad experience yesterday, one would have thought that ill fate will not come knocking back again so soon. While I was responding to an alarm, I was the one actually alarmed (an attempt on humour) to find the index table covered with grease stains. The phenomena itself is not uncommon but the sheer quantity just bogs down the mind. Soon I spotted the leaking grease supply line and quickly inform the assembly supervisor. However, owing to tight production schedule, production must go on so the problem cannot be rectified immediately until the green light is given from the assembly supervisor. Then, the supply line is stopped and disconnected to allow further inspection. Unable to find a leaky fault on both connecting ends, the technician opt to fastened both ends even more tightly and succeeded in ending the leak. I am actually quite relieved a there is no repeat of yesterday situation because you can't be sure to be lucky to have a spare part lying around somewhere in good condition.

Internship-Week 10:Wednesday

A hectic morning and what a way to begin a new day. There was a slight malfunction on one of the assembly machine, well it wouldn't actually resulted in a NG product but having a caretaker by its side 24/7 ain't a good option either. The robotic arm is supposed to pick up the futa from the feeder and placed onto the index table. Somehow, when the arm travel downwards, it's smooth sailing but it can't return back to its original position, got stuck 3/4 of the way back. A common practice is to replace the part with a existing functioning part from another assembly machine, due to some circumstances the part cannot be remove and the move aborted. So, we literally hunted around all the toolboxes and fortunately to have found some in different sizes. The attempt to remove the spoiled mechanism- a linear bearing failed and ended up unable to salvage it, leaving no choice except replacing it entirely. Most importantly, the situation shows how hopeless when we are up against uncommon malfunction as not all spare parts are readily available. Not to mention the bureaucracy tape and cost cutting method of top management that is ever frustrating.