PERODUA ENGINE MANUFACTURING REPORT

PERODUA ENGINE MANUFACTURING SDN BHD
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Malaysia-Japan International Institute of Technology
Universiti Teknologi Malaysia
AHMAD SYAFIQ ASYRAF BIN AHMAD
SABRI
920602-03-5625
A11MJ0004
BACHELOR OF MECHANICAL PRECISION
ENGINEERING
CHECKED/APPROVED BY
SUPERVISOR: ROSLI BIN MD TAWIL
(Asst. Manager)
CASTING SHOP
Perodua Engine Manufacturing Sdn Bhd Rawang, Selangor
Darul Ehsan, MALAYSIA
14TH
JULY – 5TH
SEPTEMBER 2014

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TABLE OF CONTENT
NO TITLE PAGE
1.0 ABSTRACT & ACKNOWLEDGE 3-4
2.0 INTRODUCTION 4
2.1 PURPOSE OF THE TRAINING 5
2.2 OBJECTIVES OF THE TRAINING 5
2.3 LEARNING OUTCOMES 5
3.0 COMPANY INFORMATION 5
3.1 COMPANY OVERVIEW 6-8
3.2 PERODUA VISION AND MISSION 9-10
3.3 CMK ORGANIZATION 11
4.0 GENERAL STATEMENT OF THE TRAINING
4.1 INTRODUCTION 12
4.2 CASTING SHOP DIVISION 12-14
4.3 TASK SPECIFICATION SUMMARY 15
4.4 SCOPE OF WORK, TRAINING AND PROJECT CARRIED OUT 16-27
5.0 CONTENT OF TRAINING
5.1 TRAINING CLASS ATTENDED 28
5.2 MEETING 29-30
5.3 SELF-LEARNING 30
5.4 PRESENTATION 30
5.5 REPORT PREPARING 30
6.0 CONCLUSION 31
7.0 REFERENCES 32
8.0 APPENDICES 33-37

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1.0 ABSTRACT
Universiti Teknologi Malaysia (UTM) offer industrial training course for all
students in UTM before they are qualified to graduate from the university.
Industrial training is a prerequisite for all students taking Bachelors Of
Mechanical Precision Engineering and all engineering students must complete
the training before the last semester. The industrial training is the platform for
the students to have the experiences on the working field by applying the
knowledge that the students gain from the university. Choosing the right path
to do the industrial training is the key for receiving valuable experiences and
knowledge on the steps for applying jobs after the students graduate. The
industrial training is also a platform for students to choose the company that
suits the student’s interest of working.
The starting date for the industrial training is 14th
July 2014 and the completion
date is on 5th
September 2014. Perusahaan Otomobile Kedua Sdn Bhd
(PERODUA) is the selected company that offers the industrial training. In
Perodua, the company provides many useful information and valuable
experiences about the manufacturing of a car. The car is produced from raw
materials until complete built unit (CBU) and each process consists of many
steps that need to be done according to the schedule and with high standard
of quality. The steps to produce a good quality of car require team works
attitude among Perodua staff. The implementation of team works attitude
generates a strong company that can generates high profit and will benefits
the Perodua staff and also the country.
Industrial training is a hand on experience after learning the concept or theory
in class. The training will motivate the students to increase their knowledge
not only in theory parts but also on the practical parts. The training also gives a
true picture in industry life and students must face the pressure and workload
that they receive during the training period. In advance, students will also have
the willing to perform better for the remaining study semester to receive a
good job with excellent salary after graduate. The industrial training is one of
the best methods of study after learning the concepts and theory in university.
The training also provides the first valuable introduction to the working field.

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ACKNOWLEDGEMENT
Alhamdulillah, praise to Allah SWT The Almighty God with His willing and His blessing, I am
able to finish my Industrial Training at Perodua Engine Manufacturing Sdn Bhd, PEMSB
within two months duration, begun on Jun 14th July 2014 and finished on September 5th
2014.
A deepest appreciation to my family, my friends for supporting me all the time. I like to
thanks for PERODUA, to take me as a practical trainee in the company. Not to be forgotten,
commitments from Dr. Aung Lwin Moe, faculty supervisor to come, visit, and assess me.
Deeply thanks to En Mohd Najib Bin Omar, HOD of Casting Shop, EN Rosli Bin Md Tawil,
Assistant Manager as my supervisor and all the team members casting shop department for
the helps, guidance, encouragement, advices and ideas that have been devoted to me. To
others department, human resources, thank you for being nice whenever we needs to work
together. I will utilize all the knowledge that being taught when facing the working world
soon and during my studies, in sha Allah. In addition, I would like to extend my gratitude to
all my trainee friends for the encouragement and helps during the time. The bond that has
been build will always be remembered, PERODUa.
Thank You again to my team members, PERODUA and Dr Aung Lwin Moe.
2.0 INTRODUCTION
Industrial Training (IT) is a student placement in an industry or outside organization (locally
or abroad) for a period of eight (8) weeks. The IT is designed for a student to practice
knowledge gained at university in the workplace as part of the fulfilment of the Bachelor
Degree Award.
a) It is compulsory for every MJIIT undergraduate student to undergo Industrial training for
a specified period of time under the course code of SMJG 3206.
b) The training serves as an exposure to the real work environment so that the student can
relate theories learned in class and apply them in the workplace to prepare them for their
future career as a professional engineer.
c) The students are placed in industries related to their areas of studies for a period of eight
(8) weeks. The word ‘industries’ here include the whole of engineering activities such as
consultancy, research and development, manufacturing etc. and the industry can be local or
overseas. The training should provide workplace experience that requires the student to
practically do the task and be able to apply their knowledge in the industrial setting. Every
student is required to submit a written report based on their industrial training experience.

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2.1 PURPOSE OF THE TRAINING
The goal of IT is to enhance the engineering knowledge and skills of the student in their
respective field of study and assist them towards becoming a creative and competent
professional engineer.
The primary objective of the IT is to strengthen and broaden the students' understanding of
current practice and knowledge of the latest developments through exposure to a real-
working environment and obtained during the training period. In addition, the students are
also expected to relate and apply their theoretical knowledge to solve real problems,
understanding the requirements of clients and society as a whole. Subsequently, the
knowledge gained during IT is expected to be useful for the students to undertake life-long
learning as well as to give them sufficient knowledge useful in obtaining employment upon
graduation.
2.2 OBJECTIVES OF THE TRAINING
The objectives of IT are to provide:
i) An exposure to the students of the real working environment in their respective field of
study.
ii) Platform for students to apply their academic knowledge and skills in the real working
environment.
iii) Training ground for students to communicate and interact effectively at all levels.
iv) Training experience for the students to write a technical report with regard to their IT.
v) An environment to nurture the spirit of team-working.
vi) An opportunity to exercise professional ethical values.
vii) Linkages between university and industry.
viii) Provide knowledge to students’ subsequent learning process at the university.
2.3 LEARNING OUTCOMES
At the end of IT, the students should be able to:
i) Apply the knowledge obtained at University to their working experience.
ii) Demonstrate their ability to work and adapt to an actual working environment.
iii) Demonstrate a professional commitment to ethical practice on a daily basis.
iv) Organize flow of work to evaluate system operational performance.
v) Write technical documents and give oral presentations related to the completed tasks.

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3.0 COMPANY INFORMATION
3.1 COMPANY OVERVIEW
The Perusahaan Otomobil Kedua Sendirian Berhad (Second Automobile Manufacturer
Private Limited), usually abbreviated to Perodua, is Malaysia's second largest automobile
manufacturer after Proton. It was established in 1992 and launched their first car, the
Perodua Kancil in August 1994.'M2' refers to the codename which was used when the
project to establish Perodua was still Top Secret. The shareholders of Perodua are UMW
Corporation Sdn Bhd with 38% stake, Daihatsu Motor Co. Ltd. (20%), MBM Resources Bhd
(20%), PNB Equity Resources Corporation Sdn Bhd (10%), Mitsui & Co. Ltd (7%) and Daihatsu
(Malaysia) Sdn Bhd (5%).
Perodua mainly produces minicars and superminis and does not have models in the same
market segments as Proton. They do not design or engineer their main components such as
engine and transmission in house. Perodua cars have historically used Daihatsu component
designs. Daihatsu held a 20% stake in Perodua at the company's launch, increasing this to
25% in 2001 and then to 35%. In 2004 Perodua started assembling the Toyota Avanza at
their plant in Rawang, for sale in Malaysia.

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Perodua has sold over 189,000 vehicles in 2012, which is its highest ever sales record. Its
estimated market share in Malaysia of 30.2 per cent. It is planning to set up a second car
manufacturing plant from the planned $770 million investments in the coming years.
The company started operations in 1994 and the ever so popular Perodua Kancil was
introduced to the Malaysian market in August the same year. To date, the following vehicles
have rolled out of the Perodua plant:
The Perodua Kancil - 1994
The Perodua Rusa - March 1996
The Perodua Kembara - August 1998
The Perodua Kenari - June 2000
The Perodua Kelisa - August 2001
The Perodua Myvi - May 2005
The Perodua Viva - May 2007
The Perodua Nautica 4WD - May 2008
The Perodua Alza – November 2009
As at end of May 2011, Perodua has sold some 1.9 million units of vehicles of various
models.
3.1.1 PERODUA’S PLANT
Perodua headquarters is located on an 138-hectare site in Sungai Choh, Rawang, Selangor
Darul Ehsan. It houses among others Perodua corporate building, R&D testing laboratories
and styling studio, vehicle test track, manufacturing plant, engine plant, pre-delivery
inspection area, vehicle distribution stockyard and parts warehouse.

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Figure 1 : Map of Perodua
3.1.2 PERODUA GROUP
 Perodua Auto Corporation Sdn Bhd, PCSB (400745K) was established in the final
quarter of 2001. Besides Perodua, the two other joint venture partners of PCSB are
Daihatsu Motor Co. Ltd. and Mitsui & Co. Ltd both of Japan. The manufacturing
operations of the Perodua Group are being managed by PCSB.
 Perodua Sales Sdn Bhd, PSSB (066332U) is responsible for the sales, marketing, and
distribution of all Perodua vehicles as well as after sales service and spare parts
operations.
 Perodua Manufacturing Sdn Bhd, PMSB (095999T) is the company responsible for
the manufacturing of Perodua vehicles.
1. Corporate building
2. Research & Development (R&D)
3. R&D Test Track
4. Press / Stamping Shop
5. Body / Welding Shop
6. Paint Shop
7. Assembly Shop
8. Logistic
9. Pre-Delivery Inspection (PDI)
10. Accessories
11. Distribution
12. Car Stockyard
13. Parts Warehouse
14. Perodua Learning Centre
15. CMK; Engine (K) Shop
16. CMK; Casting & Machining Shop
17. CKD Warehouse
18. Bumper Paint
1
2
3
4 5
68
7
910
11
1213
14
15
16
17
18

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 Perodua Engine Manufacturing Sdn Bhd, PEMSB (400706M) undertakes the
assembly of the vehicle engines and also manufacturing of selected engine
component parts.
3.1.3 PERODUA ENGINE MANUFACTURING SDN BHD (PEMSB)
Figure 2: PEMSB building
Perodua Engine Manufacturing Sdn Bhd (PEMSB) manufactures engine parts, assembles and
supplies engines parts and complete-assembled engines to other subsidiary company and
other company.Some of the engine parts are made and assembled inside the Plant 2 or as
known as CMK(Casting,Machining,Kumitate(Engine Assembly)). All of the Perodua models
are derivation of Japan Daihatsu models, either badge engineered, redesigned or localized
version of their current or previous models. Some of the models are being exported to other
country such as Japan, Pakistan, Indonesia and UK.
3.2 PERODUA VISION AND MISSION
3.2.1 VISION
To be the most preferred automotive brand renowned for products and services of excellent
quality which contributes to the development of the nation.
3.2.2 MISSION
To be a world class automobile company renowned for excellent quality and reliability, we
aim to realise our vision by:

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1) Professionalism in all our operations
2) Efficiency in utilising technologies and available resources
3) Resilience in meeting our challenges
4) Optimising benefits to customers and stakeholders
5) Dedication towards social responsibility to community, the environment and
development of competent workforce
6) Uniqueness in our products
7) Aspiration to glorify the name of Perodua
3.2.3 CMK VISION AND MISSION
VISION : Towards Global and Competetive Engine Manufacturing Plant By 2015
MISSION : Creating Smooth Operation With Good Quality to Costumers
Figure 3: CMK MISSION

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3.3 CMK ORGANIZATION
Chart 1 : 2014 CMK Unit Manufacturing Organization
Chart 2 : CMK Organization Chart

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4.0 GENERAL STATEMENT ON THE TRAINING
4.1 INTRODUCTION
On 14th July 2014, I came to Perodua Engine Manufacturing Sdn Bhd (PEMSB) to report as a
practical trainee in Engineering Department, Unit Manufacturing Division. Together with
other practical trainee from the same Faculty of Malaysia Japan International Institute of
Technology (MJIIT), Universiti Teknologi Malaysia had gone through the internship here for
eight weeks. We were given a short brief about department organization and functions by
Human Resource Department. Then we were divided into different division of this
department. I have been placed into Casting Shop Division under supervision of En. Rosli Bin
Md Tawil, an Assistant Manager of Casting Shop Division.
4.2 CASTING SHOP DIVISION
Figure 4: Casting Shop building

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Chart 3 : Casting Shop Organization Chart
***Please Refer Appendix A for better view
Casting Shop Division was establish as a support unit, produce main aluminium base engine
parts:
1) Cylinder Head
2) Intake Manifold
To be used in PERODUA engine for Kenari, Kancil (660,850 engines), Viva (660, 850 & 1000
engines), Myvi & ALZA (1.3l, 1.5l engines). In addition, Perodua also producing Cylinder Head
CAMPRO IAFM & CPS for Proton Engine since 2005
.
Figure 5 : All type of cylinder head Figure 6: Casting Product

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4.2.1 CASTING TECHNOLOGY
PERODUA using 2 type of Casting technique:-
 Gravity Die Casting.
Using manual or robot to pour molten aluminum (±700°C) into casting die.
 Low Pressure Die Casting.
Using compressed air to inject molten aluminum into casting die.
Figure 7: Main Core making process
1
Core Making Process:
(using resin coated sand)
Produce Water Jacket Core, Oil Jacket Core
& Port Core
Die Casting Process :
1. Auto Pouring Gravity Casting ( RGDC and GDC )
2. Tilting Gravity Casting ( Intake Manifold Line )
3. Low Pressure Casting
Finishing Process :
1. Manual Knock Out
2. Sprue/Gate Removing
3. Knock Out ( Machine )
4. Riser Cutting
5. Deburring
6. Final Inspection

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4.3 TASK SPECIFICATION SUMMARY
Chart 4: Master Schedule of Internship Programme
***Please Refer Appendix B for better view

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4.4 SCOPE OF WORK, TASKS AND PROJECT CARRIED OUT
Below are my activities during the Industrial Training starting from 14th July 2014 until 5th
September 2014 at Perodua Engine Manufacturing Sdn Bhd:
4.4.1 MAIN TASK
PRIORITY!
Kaizen and Improvement Activities ( K3 Main Core Cooling Booth )
 Focus area : K3 Low Pressure Line
 Problem :
Current Core Temperature high (≈55°C)
 Objective :
Target Output (≈35°C) nearly surrounding temperature and can touch main
core without using glove.
4.4.1.1 MAIN FOCUS WORKPLACE TASK
Figure 8 : Current cooling booth in K3 line
At first, I have given a special task which is to replace current cooling booth with new one as
long as the current one generally not 100% functioning well.
1
1
1
1
1
1
1
1
1
1

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4.4.1.2 SELF STUDY (ANALYSIS)
I have done my self-study basically focusing on analysis at first based on the real time
observation.
Figure 9: Side view of recent cooling booth
From figure 9, we cannot see clearly what is going on inside. This is very important for the
future maintenance and quality check countermeasure future.
Figure 10: Inside recent cooling booth view
* 8 Small Fans
* 2 big Fans
* 1 Spot
Cooling (Human)

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From figure 10, because not all the 8 small fans and 2 big fans functioning well, it results
very bad ventilation system for the current cooling booth. Furthermore 1 spot cooling used
is not good enough and such a waste because actually for human (operator) usage. One
main factor for the bad ventilation system caused by there is no heat (hot air flow) expel
outside. It result the accumulation of the hot air trapped inside the cooling booth.
Figure 11: Buffer zone for main core
From figure 11, the buffer zone is exist next to current cooling booth because all the main
core outflow from the current cooling booth is not achieving the target temperature or
easily understand cannot be touch with bare hand. This process actually waste in term of
space and time because using just the conventional fan to cool it down nearly surrounding
temperature.
Figure 12: Temperature probe
By using the temperature probe and timer, I have taken the main core temperature with 3
different conditions. Here are the explanations:
Natural Convection: Let the main core cool down naturally within surrounding
temperature.
Force Convection: Let the main core cool down by using blower
Cooling Booth Analysis:
o Using temperature
probe
o Plot the graph

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All the temperature is recorded in degree Celsius and time in second.
Figure 13: Analysis data recorded and tabulated.
Figure 14: Graph of different cooling type (condition) versus time graph
From figure 14, as we can see the natural convection data shows very slow rate decreasing
in temperature compared to both force convection and current cooling booth. By first 120
second shows the same rate decreasing of temperature. It changes rapidly at 180 second
and above until the 720 second which is 12minutes. The current cooling booth takes
approximately 12 minutes to cool the main core nearly 48°C while by using force convection
the results shows temperature approximately 35°C which is the same as surrounding
temperature.
By the way, the current cooling booth contains 12 polybox at one time. From the results
obtained, by using the force convection the main core temperature achieved nearly
surrounding temperature which is 39°C which is still relevant to be touch without glove
(bare hand). Bear in mind this condition is without the proper ventilation system so might
get better result. This means for the future cooling booth we just can only run 10 polybox at
one time which the ideal time is 600 second just about 10 minutes.
In terms for future design as what can I say is the size of cooling booth might be
smaller/shorter compared to the current cooling booth. In addition, we can totally maximise
space for others support activity/maintenance by not using the buffer zone anymore.
Time 60 120 180 240 300 360 420 480 540 600 660 720
NaturalConvection 156 144 139 131 120 117 110 105 99 95 91 88
CurrentCoolingBooth 156 110 80 78 77 74 63 60 58 55 52 48
ForceConvection 156 99 90 82 77 70 64 57 48 39 37 35

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4.4.1.3 DRAWING DRAFT PROJECT
All the sketches & drafts for future plan cooling booth was presented with the supervisor
and have a discussion all about material selection, mechanism, specification to be used
before the project is approved and proceed with the fabrication process. Below are the
sample of sketches and drafts.
Figure 15: The sketches and drafts of cooling booth for both current & future design

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4.4.1.4 FABRICATION AND INSTALLATION
Figure 16: Aluminium profile as the main material selection
From figure 16 shows aluminium profile is as the main material selection for the whole main
body of the cooling booth.

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Figure 17: Roller used for the moving part
From figure 17 shows the usage of roller for the moving mechanism. The mounting for the
roller is quite easier with bolt and nut attached within aluminium profile. Each end of roller I
have placed one for stopper and another one is for hold the polybox.
Figure 18: Acrylic as the cover
From figure 18, I have decided to used acrylic as the main cover because it is very good
looking as long as transparent so we can see crystal clear what is going on inside. Besides, it
is good for future maintenance so we can detect if some kind of malfunction or abnormal
inside.

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Figure 19: Acrylic installation problems detected
Figure 20: Mounting for the piping system and special nut
From figure 20 shows how the mounting for the piping have done. Kaizen team members
and I work together to make a lot of customs bracket. Next is they called it “special nut” got
it from the PERODUA GLOBAL. This special nut can solved a lot of problems occur during the
aluminium profile critical corner. It can be knock easier directly inside the gap of aluminium
profile without to reassemble back each corner.
When the acrylic installation,
there is a problem especially for
each corner because of the
aluminium profile bracket. As the
cooling booth need to be no
small gap for unnecessary air.
Thus, for the countermeasure,
we have to make our own
outside bracket by using 3mm
rectangle plate, which is the
rectangle shape and “L” shape.

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Figure 21: 3 inch pipe used/machine shotblast
From figure 21 shows the 3 inch pipe we used for the internal piping system air distribution.
Before we use, we need to “shotblast” it to remove any unnecessary oil/rust to make it
easier for the next painting job. The same concept by using sand paper and this machine
shotblast is more efficient and holistic clearance.
Figure 22: Pipe flange used for attachment

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From the figure 22 shows the pipe flange we make it custom for the each 3inch and 6 inch
pipe attachment/coupling in between the acrylic.
Figure 23: 3mm rectangle plate used for small fan housing
From figure 23 shows 3mm rectangle plate used for 6 small fans housing. We used 1 small
plate for 2 small fans each. We used plasma cutter with adds tools of the special features for
very accurate circle cutting and fast enough. But in term of “precision” engineering, CNC
works better but complicated in my case.

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Figure 24: Polycarbon used for the roof top cover
From figure 24 shows blue polycarbon we used for the top roof cover because it is easier to
handle/cut, good looking and convenient for future maintenance.
Figure 25: Polycarbon screw to aluminium profile and PVC Curtain used
From the figure 25 shows the blue polycarbon was screwed to the aluminium profile. In
addition, each inflow and outflow we attached with PVC Curtain used to block the outside
air from go inside and inside air not to go outside. If there are fewer gaps, there will be
more effective cooling process. Thus there is less probability of unnecessary and waste air
flow.

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Figure 26: Mechanically Fabrication finished on 2nd September
From figure 26 shows the mechanical fabrication is done almost approximate 90% on 2nd
September 2014 and this is earlier than expected plan. Thus the left items including wiring
for all those small fan, blower and control panel were proceed on 3rd September 2014.
Furthermore, the flexible air ducts host also pending for the installation on the same date
even though the blower arrived earlier than expected.
Figure 27: Silent Blower

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5.0 CONTENT OF TRAINING
All the given related work during the Industrial Training based on the main task mentioned
earlier in chapter 4.4. Here are the lists of minor/work done in details.
5.1 TRAINING CLASS ATTENDED
5.1.1 Basic shop training
 Organization briefing
 Layout casting shop - tour briefing
 Casting shop plant tour
5.1.2 Dojo Training (Basic Education)
All the classes take place in Casting Shop except for the Safety Dojo located nearby the
Machining Shop. Average for each class takes minimum 2 hours to 6 hours.
 Safety & 4’S Dojo
Figure 28: Safety & 4s’ Dojo
 Casting Dojo (Skill)
Figure 29: Casting Dojo

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 Master Schedule Class
The master schedule class was held for all the practical trainees to learn from how
Perodua’s employee real time working. The class was conducted by En Mohd Najib Bin
Omar, the HOD for Casting Shop himself.
***Please Refer Appendix C for sample note
5.1.3 On Job Training
Before I proceed with the project given, I have attend production line training accompanied
by each team leader to get better understanding especially on K3 line because the project
given have relationship and need to understand.
 Training EJ line & K3 line ( Main Focus On K3 Line )
Figure 30: EJ and K3 line
5.2 MEETING
A meeting is a gathering of people to brainstorming or exchange information, plan join
activities, decision making, or actions that have been agreed. In the meeting I had attended,
I learned how the professional meeting has been conducted. It is good experience for me
every day we discuss and inform anything related yesterday’s progress and today’s plan
besides any highlighted issues to be mentioned. Meeting that I followed was:

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Figure 31: Die Maintenance & Emirates Meeting Room
 Kaizen Team Members daily meeting nearby the die maintenance after the
main meeting in front of the Casting Shop
 Team Management daily meeting at the Emirates Meeting Room located
inside the Casting Shop, in front of the EJ line.
5.3 SELF-LEARNING
About self-learning, for example before I attend on line production especially K3 line
training, as my supervisor gave me the “QCPC” unit production engineering, I spent my time
to read, understand anything related on K3 line training all about cylinder head casting
process from the beginning of aluminium ingot melting to the last heat treatment of
cylinder head for better earlier vision and understanding learning process.
***Please Refer Appendix D for QCPC sheet
5.4 PRESENTATION
Presentation for me especially in an engineering environment is the best practice to
convince people. Its needs a perfect preparation for perfect outcome. So far I have a lot of
opportunity to make a presentation during my internship for example during the Internal
Presentation (Casting Shop Management) and during CMK Presentation (Top Management)
both for progress and final presentation. For me these are most valuable experiences to
gain here all about confident level, the way to express the idea, and sharing great ideas. All
the cultivate feedback from my presentation is a part of learning process to be better for
future’s working environment.
***Please Refer Appendix E for progress and final presentation slide
5.5 REPORT PREPARING
The report needs to be prepared for the authorities’ submission especially for the Casting
Shop and CMK (Top management) to be checked. The report needs to be submitting before
the final presentation on 3rd September 2014 for the higher management to be approved.

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6.0 CONCLUSION
The main reasons for an engineering student to do Industrial Training are so they are well
prepared and get the big picture for a real job in their chosen field when graduate. It’s a
great opportunity for me to apply what I’ve learned at University to work in real time
situation I will come up against when I start my career. There are 3 main objectives
highlighted for my Internship in Casting Shop to be achieved once I finish my practical
training:
1) To link up an engineering theoretical knowledge into real application
2) To practice professionalism working environment to polish employability potential
3) To expose in critical thinking and decision making as a professional employee.
Industrial training gives me great experience during my Bachelor of Engineering degree:
• First-hand experience working as an engineering professional,
• Apply my technical knowledge and engineering methods to a real-life situation.
• Work with other engineering professionals.
• Experience what it’s like to work in a professional organization.
• Increase my technical, interpersonal and communication skills, both oral and written.
• Observe interactions of engineers with other professional groups.
• Witness the functioning and organization of business and companies.
All the skills gained during my internship are really made feel comfort with the field I choose.
I able to learn more about this field especially in the real world as an engineer. I like to
conclude that, industrial training is a best practice giving opportunity to student adopting
real work as an engineer. Thank you PERODUA.

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7.0 REFERENCES
1) MOHD NAJIB BIN OMAR
HEAD OF DEPARTMENT, CASTING SHOP
2) ROSLI BIN MD TAWIL (SUPERVISOR)
ASSISTANT MANAGER, CASTING SHOP
3) MOHD NIZAM BIN ZAKARIAH
IVENTORY CONTROLLER, CASTING SHOP
4) NORISHAH BINTI JAAFAR
CMK TRAINER, UNIT MANUFACTURING ADMINISTRATION
5) QCPC (UNIT PRODUCTION ENGINEERING)
PROCESS SPECIFICATION & DETAILS ON K3 LINE
6) MASTER SCHEDULE NOTES
PREPARED BY MOHD NAJIB BIN OMAR
HEAD OF DEPARTMENT, CASTING SHOP
7) PERODUA WEBSITE
http://www.perodua.com.my/corporate/company

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8.0 APPENDICES

Page 34

Page 35

Page 36

Page 37

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LIST OF APPENDICES:
1) APPENDIX A (Casting Shop
Organization Chart)
2) APPENDIX B (Master Schedule of
Internship Programme)
3) APPENDIX C (MASTER SCHEDULE
NOTE)
4) APPENDIX D (QCPC SHEET)
5) APPENDIX E (PROGRESS AND
FINAL PRESENTATION SLIDE)

PERODUA ENGINE MANUFACTURING REPORT

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