Faculty of Electrical Engineering Technology

INDUSTRIAL TRAINING REPORT

MUHAMMAD AIDIL DANIAL BIN AZIZ

BACHELOR OF ENGINEERING
(MECHATRONIC ENGINEERING)

FACULTY OF ELECTRICAL ENGINEERING TECHNOLOGY

UNIVERSITI MALAYSIA PERLIS

2024
 Faculty of Electrical Engineering Technology

INDUSTRIAL TRAINING REPORT

(EMJ30105)

At

MINEBEA ELECTRONIC MOTOR (M) SDN BHD

LOT 12, JALAN PKNK UTAMA,
KAWASAN PERINDUSTRIAN SUNGAI PETANI,
08000 SUNGAI PETANI,
KEDAH DARUL AMAN

NAME : MUHAMMAD AIDIL DANIAL BIN AZIZ

MATRIC NO : 221062284
PROGRAM : BACHELOR OF ENGINEERING
(MECHATRONIC ENGINEERING)
ACADEMIC SESSION : 2023/2024
 Faculty of Electrical Engineering Technology

ACKNOWLEDGMENT

I would like to express my sincere gratitude to Minebea Electronic Motor (M) SDN
BHD for providing me with the opportunity to complete my industrial training program
at their esteemed organization. I am deeply appreciative of the support, guidance, and
encouragement offered throughout my time here. Special thanks go to Madam Ruslina
Abu Yaziz, manager of the Process and Product Quality Assurance (PPQA) for their
invaluable mentorship and expertise, which greatly contributed to my understanding of
Minebea standard processes that are implemented and followed by projects and
departments.

I would also like to acknowledge the entire PPQA and Quality Control (QC) team
for their collaboration and willingness to share their knowledge. Their professionalism
and support have greatly enriched my learning experience.

Additionally, I am grateful to Ts. Ahmad Firdaus bin Ahmad Zaidi for taking the
time to review my work, providing constructive feedback, and encouraging me to grow
professionally.

Finally, I extend my gratitude to my educational institution, University Malaysia

Perlis (UniMAP), for facilitating this training opportunity, and to my lecturers and
colleagues who provided continuous support and encouragement.

Thank you all for helping to make my industrial training a productive and fulfilling
experience.

iii
 Faculty of Electrical Engineering Technology

APPROVAL AND DECLARATION SHEET

iv
Faculty of Electrical Engineering Technology

v
 Faculty of Electrical Engineering Technology

ABSTRAK

Laporan ini mendokumentasikan pengalaman latihan industri di Minebea

Electronics Motor (M) Sdn. Bhd., sebuah anak syarikat MinebeaMitsumi Inc. yang
terletak di Sungai Petani, Kedah, Malaysia. Latihan ini memberi fokus kepada
pendedahan praktikal terhadap proses pengeluaran dan jaminan kualiti syarikat,
khususnya dalam jabatan Process and Product Quality Assurance (PPQA) dan divisyen
Press 1 yang bertanggungjawab untuk pemasangan teras lengan. Aktiviti utama termasuk
pemantauan pengeluaran, pelaksanaan pemeriksaan kualiti, dan memastikan penjajaran
dengan piawaian kualiti yang ditetapkan. Beberapa jenis model motor turut
diperkenalkan, seperti MN36 Electronic Parking Brake (EPB), Pan14, dan siri
SA/SE/SU/18/24/30, serta penggunaan peralatan untuk kawalan kualiti komponen.
Melalui projek dalam jabatan PPQA, latihan ini menekankan peranan automasi dan
analisis data dalam mengurangkan variabiliti pengeluaran serta meningkatkan konsistensi
produk. Selain itu, tugasan berkaitan dengan pemasangan teras lengan memberikan
pemahaman mengenai bagaimana langkah kawalan kualiti yang ketat mempengaruhi
kebolehpercayaan dan kecekapan produk akhir. Pengalaman ini menghubungkan
pengetahuan akademik dengan aplikasi praktikal, mempertingkatkan kemahiran teknikal
dan pemahaman mengenai pengurusan kualiti dalam persekitaran perkilangan. Laporan
ini diakhiri dengan cadangan untuk penambahbaikan masa depan dalam proses PPQA
bagi menyokong kecemerlangan operasi di Minebea Electronics Motor.

vi
 Faculty of Electrical Engineering Technology

ABSTRACT

This report documents the industrial training experience at Minebea Electronics Motor
(M) Sdn. Bhd., a subsidiary of MinebeaMitsumi Inc., located in Sungai Petani, Kedah,
Malaysia. The training focused on hands-on exposure to the company’s production
processes and quality assurance practices, specifically within the Process and Product
Quality Assurance (PPQA) department and the Press 1 division responsible for armature
core assembly. Key activities included monitoring production, conducting quality
inspections, and ensuring alignment with established quality standards. Multiple types of
motor model are being introduced, for example, MN36 Electronic Parking Brake (EPB),
Pan14, and SA/SE/SU/18/24/30 series. As well as the uses of equipment to make the
quality checks the parts Through projects in the PPQA department, the training
emphasized the role of automation and data analysis in reducing production variability
and enhancing product consistency. Additionally, tasks related to the armature core
assembly provided insights into how rigorous quality control measures impact the
reliability and efficiency of final products. This experience bridged academic knowledge
with practical applications, enhancing technical skills and understanding of quality
management in a manufacturing environment. The report concludes with
recommendations for future improvements in PPQA processes to support operational
excellence at Minebea Electronics Motor.

vii
 Faculty of Electrical Engineering Technology

TABLE OF CONTENTS

ACKNOWLEDGMENT iii

APPROVAL AND DECLARATION SHEET iv

ABSTRAK vi

ABSTRACT vii

TABLE OF CONTENTS viii

LIST OF TABLES xi

LIST OF FIGURES xii

CHAPTER 1 INTRODUCTION 11
1.1 Introduction of Industrial Training 11
1.2 Industrial Training Objectives 11
1.3 Name of the Company 12
1.3.1 Head Company 12
1.3.2 Internship Company 12
1.4 Address of the Company 12
1.5 Company Logo 12
1.6 Overview of Minebea Electronics Motor (M) Sdn. Bhd. 12
1.7 Background History of MinebeaMitsumi and 13
Minebea Electronics Motor (M)
1.8 Company Vision and Objectives 13
1.9 Department Assigned by the Company 14

viii
 Faculty of Electrical Engineering Technology

CHAPTER 2 15
2.1 Introduction 15

2.2 Working Hours 15

2.3 Summary of Logbook by Weeks 16

2.4 Rules and Regulations 18

2.4.1 5S Program 18

2.4.2 Monthly assembly 19

2.4.3 Morning Briefing 20

2.5 Operational Intelligence of Quality Check 20

2.6 Parts and Product for PPQA Inspection 22

2.6.1 Check sheet 22

2.6.2 Press 1 and Press 2 23

2.7 Equipment for Quality Checking 26

2.7.1 Manually operated equipment 28

2.7.2 Semi-automatically operated equipment 32

2.7.3 Automatically operated equipment 36

2.8 Armature Core Assembly 39

2.9 Overview of this chapter 40

CHAPTER 3 DISCUSSION AND RECOMMENDATION 41

3.1 Introduction 41
3.2 Discussion 41
3.3 Recommendations 43

CHAPTER 4 CONCLUSION 44

ix
 Faculty of Electrical Engineering Technology

REFERENCES 45

APPENDICES 46

Appendix A 46
Appendix B 47

x
 Faculty of Electrical Engineering Technology

LIST OF TABLES

Table 2.2.1: Schedule between 3 Groups for normal working days 15

Table 2.2.2: Schedule between 3 Groups for Friday 16
Table 2.3: Overview of the logbooks weekly main topic 18

xi
 Faculty of Electrical Engineering Technology

LIST OF FIGURES

Figure 1.5: MinebeaMitsumi Logo 12

Figure 1.7: The location of other Minebea’s plants and sale offices 13
Figure 1.8: Real life picture of Minebea Electronics Motor (M) plant 14
Figure 2.4.1: Illustration of 5S program 19
Figure 2.4.2: Pictures taken during the monthly assembly 20
Figure 2.5: Example of an OI 21
Figure 2.6.1: (a) Example of press core assembly check sheet 22
Figure 2.6.1: (b) Example of armature core check sheet 23
Figure 2.6.2: (a) EPB Armature Core being tested for its internal dimension (ID) 25
Figure 2.6.2: (b) Press 1 parts in a line 25
Figure 2.6.2: (c) One of the armature core’s models which is 25
being compared to a finger
Figure 2.6.2: (d) Bracket from Press 2 being analysed under Keyence machine 26
Figure 2.7: (a) Shows the box full of jigs for measuring frame for PWN10A model 27
Figure 2.7: (b) shows side by side of two types of measuring jig different in lengths 27
Figures 2.7: (c) Expiry date are visible from the equipment above 27
Figure 2.7.1: (a) Picture of Pic Tester and Push/Pull Gauge 28
Figure 2.7.1: (b) Picture of Digimatic Indicator 29
Figure 2.7.1: (c) Calliper measuring armature core 30
Figure 2.7.1: (d) Microscope as one of the manually operated equipment 30
Figure 2.7.1: (e) Pic Tester measuring 31
Figure 2.7.1: (f) Pin/Plug gauge for EPB model 32
Figure 2.7.2.: (a) Tension Machine use to check the strength of armature 33
Figure 2.7.2: (b) Picture of Measurescope 34
Figure 2.7.2: (c) Figures shows the CCD Micrometer 35
Figure 2.7.3: (a) Shows the Keyence Machine measuring armature core deflection 37
Figure 2.7.3: (b) Keyence machine measuring the shearing angle of the EPB armature 38
Figure 2.7.3: (c) Keyence Machine in home page and measuring EPB bracket 38

xii
 Faculty of Electrical Engineering Technology

CHAPTER 1

INTRODUCTION

1.1 Introduction of Industrial Training

Industrial training for Mechatronic Engineering students at Universiti Malaysia
Perlis (UniMAP) is an essential component of the degree program, designed to bridge
theoretical knowledge with practical industry experience. Typically conducted during the
3rd years of study (2nd year of study for Ex Diploma), the training places students in
relevant industries where they can apply their skills in areas such as automation, robotics,
control systems, and electronics. Students work on real-world engineering problems,
enhancing their technical skills, problem-solving abilities, and understanding of
professional practices. This hands-on experience is crucial for preparing graduates for the
demands of the engineering field and helps in networking and career development. In this
case, this report will base on Minebea Electronic Motor (M) Sdn. Bhd. and the student’s
experiences during the internship.

1.2 Industrial Training Objectives

i. To provide students with firsthand experience in the mechatronics industry,
showing how classroom theories are applied in real-world situations.
ii. To familiarize students with operational procedures, machinery, and
equipment in mechatronics, including how mechanical, electronic, and control
systems integrate.
iii. To allow students to observe how engineers address technical problems,
improving their analytical skills.

11
 Faculty of Electrical Engineering Technology

1.3 Name of the Company

1.3.1 Head Company

MinebeaMitsumi, Inc.

1.3.2 Internship Company

Minebea Electronics Motor (M) Sdn. Bhd.

1.4 Address of the Company

Lot 12, Jalan PKNK Utama,

Kawasan Perindustrian Sungai Petani,
08000 SUNGAI PETANI, Kedah Darul Aman, Malaysia
TEL: 60-4441-1212
FAX: 60-4441-1213

1.5 Company Logo

Figure 1.5: MinebeaMitsumi Logo

1.6 Overview of Minebea Electronics Motor (M) Sdn. Bhd.

Established in 1990, Minebea Electronics Motor (M) Sdn. Bhd. operates as a key
manufacturing hub for MinebeaMitsumi Inc. that is originated in Japan, specializing in
the production of high-quality brush DC motors. Based in Sungai Petani, Kedah,
Malaysia, the facility is positioned to meet the growing demand for electronic motors
used in diverse applications, from consumer electronics to advanced industrial systems.
The site plays an integral role in supporting MinebeaMitsumi for precision manufacturing
and quality control which will be supplied to Thailand, Cambodia, Germany, and etc.
globally.

12
 Faculty of Electrical Engineering Technology

1.7 Background History of MinebeaMitsumi and Minebea Electronics Motor (M)

Founded as a part of MinebeaMitsumi Inc., Minebea Electronics Motor (M) Sdn.
Bhd. was established to expand the company’s global footprint, particularly within
Southeast Asia. The Malaysian subsidiary contributes significantly to the company’s
manufacturing capabilities by focusing on high-volume production for international
markets and supplying motor components for in-house production needs. As
MinebeaMitsumi broadened its technological scope, Minebea Electronics Motor
Malaysia adapted by integrating advanced manufacturing techniques to keep pace with
the demands of precision motor production. This alignment ensures that MinebeaMitsumi
remains competitive in the dynamic electronic motor industry, particularly for
automotive, consumer electronics, and industrial applications.

Figure 1.7: The location of other Minebea’s plants and sale offices

1.8 Company Vision and Objectives

Minebea Electronics Motor (M) Sdn. Bhd. is committed to achieving
manufacturing excellence and maintaining high standards for product quality and
operational efficiency. The company focuses on technological innovation, adhering to
rigorous quality management practices, and fostering a culture of continuous
improvement among employees. The workforce in Malaysia is valued as a critical asset,
and the company invests in training and development to align with its vision for the 21st
century, emphasizing precision and reliability.

13
 Faculty of Electrical Engineering Technology

The production facility in Sungai Petani underscores the importance of both local
and international market demands, aiming to support various industries with reliable,
high-quality motor solutions. By remaining agile in an evolving market, Minebea
Electronics Motor Malaysia reinforces its status as a leading motor producer in the Asia-
Pacific region.

Figure 1.8: Real life picture of Minebea Electronics Motor (M) plant

1.9 Department Assigned by the Company

The department that has been assigned was Process and Product Quality
Assurance, known as PPQA. PPQA involves systematic activities aimed at ensuring that
both processes and products meet defined quality standards and customer expectations.
In a company like Minebea Electronics Motor (M), PPQA is critical to maintaining high
precision and reliability in electronic motor components, which are used in various
industries such as in cars. Through multiple quality checks, process audits, and
continuous improvement strategies, Minebea ensures that its manufacturing processes
and final products adhere to strict quality benchmarks, reducing defects and enhancing
product performance. This commitment to quality assurance not only improves customer
satisfaction but also strengthens Minebea’s reputation as a leader in high-quality
electronic motor manufacturing against the company competitors.

14
 Faculty of Electrical Engineering Technology

CHAPTER 2

INDUSTRIAL TRAINING PROJECT AND MAIN ACTIVITIES

2.1 Introduction

This chapter presents a comprehensive overview of the weekly activities

completed during the industrial training. Tasks were assigned every week and knowledge
that was provided by supervisor. The tasks are detailed with explanations to offer clarity
on the specific objectives and skills developed. During this period, the theorical
knowledge that can be applied throughout what has been learned in UniMAP was used in
the practical setting, while also adapting to the company’s standards, rules, and
professional ethics. Beyond technical tasks, this experience has deepened the
understanding of industry expectations and helped to cultivate essential skills like
teamwork, effective communication, and quality assurance in line with industry
standards. The training also allowed an observation and practice to be made for the PPQA
methods critical to maintaining the high standards upheld by Minebea Electronics Motor
(Malaysia).

2.2 Working Hours

Working hours refer to the specific times during which an employee is expected
to perform their job duties. This period typically includes a set start and end time each
day, with scheduled breaks in between, such as lunch.
The table below shows the working hours for different type of groups in Minebea
on regular working day.
Group Working Hours Break 1 Break 2 Break 3
Group 1 7.45 am - 10.30-11.00 am 2.30-3.00 pm
Group 2 - - 11.30-12.00 pm 3.00-3.30 pm
Group 3 5.45 pm 9.45-10.00 am 12.30-1.00 pm 3.25-3.40 pm
Table 2.2.1: Schedule between 3 Groups for normal working days

15
 Faculty of Electrical Engineering Technology

However, there is a difference in break time for Friday for each group. This is
because of Friday praying that must be attended by Muslim employees. Below shows the
table for the Friday schedule for each group.
Group Working Hours Break 1 Break 2
Group 1 7.45 am 9.20-9.40 am 12.50-2.30 pm
Group 2 - 9.50-10.10 am /
Group 3 5.45 pm 10.20-10.40 am 1.05-2.45 pm
Table 2.2.2: Schedule between 3 Groups for Friday

Minebea also offers overtime (OT) payment to the trainee. For 1 hour of OT work,
Minebea will pay RM4. And the payment during the off and rest day are increased to
RM38 instead of usual RM30 for degree trainee.

2.3 Summary of Logbook by Weeks

The summary of logbook is an essential aspect for the report to show the timeline
and assignments that has been given to the student. This section will be act as an overview
for the report of what the student has learned during the internship.

Weeks Description and assignments

Introduction of Minebea Electronics Motor (M)
• Briefing regarding the foundation, regulation, and details about
MinebeaMitsumishi, Inc. and its branches
1
• Uniforms distribution for the trainee
• Introduction to QC department
• Introduction to the Press 1 and Press 2
Detailed exploration of QC department
• Press 1 and Press 2 location
2 • Machine that are used in Press 1
• Introduction of the groups, workers, and position
• Types of work PPQA covering

16
 Faculty of Electrical Engineering Technology

Press 1 and Press 2 differences

• Types of armature core produced from each machine
3 • Armature core assembly line
• Types of assembly in production line
• In-depth look of
Covering other works in PPQA
• Introduction of powder coating and its model
4 • Cambodia related motor that are focusing because of audit
• Finding out the difference between normal model and customer
model
Learning about Press 2 part of PPQA
• Check sheets key-in
5 • Bracket quality checking
• Ways to handle new product
• Development of new check sheet for the new product
Customer Audit
• Preparation for the customer Audit
6
• OI placement and improving for the current OI
• Sample storing
Visiting others department
• Types of production lines, knowing the structure of other production,
7
give an insight on improvement that can be made.
• Machine keeper work and their structure
Motor assembly
8 • Visiting motor assembly for each model
• Combination of parts from Press 1 and Press 2 to become a motor
Upcoming new model discussion
• New model introduction
9
• Excel updates for new model
• New OI introduction

17
 Faculty of Electrical Engineering Technology

Round up of previous works

• Briefing of what has been learned throughout internship
10
• Culture in Minebea: Farewell Party
• Returning of Uniforms
Table 2.3: Overview of the logbooks weekly main topic

2.4 Rules and Regulations

Minebea Electronics Motor (Malaysia) Sdn. Bhd. emphasizes the importance of

maintaining a disciplined work environment and upholding safety standards across all
operations. Strict adherence to rules and regulations is crucial for ensuring not only
productivity but also the safety and well-being of employees. The company’s Code of
Conduct requires all employees to comply with workplace health and safety protocols,
emphasizing the need for a safe and controlled work environment. Additionally, as part
of MinebeaMitsumi’s global standards, the Malaysian branch focuses on ethical conduct
and environmental responsibility, promoting a culture that values safety and a positive
work atmosphere. There are few programs and event to backup these claims, which is:

2.4.1 5S Program
One of the best examples for the regulation in Minebea is that it focuses the 5S
program that has been execute for decades in Japanese workplace. The 5S system is a
workplace organization method used in Japanese industries to improve efficiency and
maintain a clean, organized environment. The 5S stands for:
i. Seiri (Sort): Remove unnecessary items from the workspace, keeping only
what’s needed.
ii. Seiton (Set in Order): Arrange tools and materials in an organized way for
easy access.
iii. Seiso (Shine): Keep the workspace clean by regularly cleaning and
maintaining equipment.
iv. Seiketsu (Standardize): Establish standard practices to maintain the first
three S's consistently.
v. Shitsuke (Sustain): Make 5S a long-term habit through regular practice
and discipline.

18
 Faculty of Electrical Engineering Technology

This system helps reduce waste, improve productivity, and create a safer, more
efficient workplace. Employees are required to do these 5S at the end of every shift and
every Friday morning. The activities include sweeping the floor, dusting the cabinets, and
wiping tables and mirror within the department vicinity.

Figure 2.4.1: Illustration of 5S program

2.4.2 Monthly assembly

In order to create a discipline environment in a working place, Minebea maintains
the need of assembly that must be attend in every first day of the month.
During the assembly, all employee regarding their position will start to group up
within the canteen vicinity. The manager of each responsible department will give the
overview of the latest achievement, losses, warnings, and monthly appreciation for the
employees that manage to stop any defects and gave an idea of a solution regarding
problems that has been going on in each department. There will be events of the month
for employees can participate and win prizes. Some of the events are blood donation event
where the employees can donate their blood to the blood bank, highest steps taken among
employees, and electrical and water waste saving.
With this, there is a clear picture of what monthly assembly in Minebea is like and
how it’s operated.

19
 Faculty of Electrical Engineering Technology

Figure 2.4.2: Pictures taken during the monthly assembly

2.4.3 Morning Briefing

In order to recap and analyze the previous quality check that has been made during
the morning and night shift, PPQA employees are required to noted down any repair,
defects and changes on the machine and parts made. The notes that had been jotted down
on the report logbook will then be read out during the morning assembly. Manager will
then determine the best possible action and analyze the possible outcomes from these
reports. By addressing the important adjustments for the product and machine, this will
allow a better understanding of previous adjustment in case of product defect. This
briefing will also allow team building among co-workers and other employees.

2.5 Operational Intelligence of Quality Check

Operational Intelligence (OI) in an industrial setting refers to real-time data

analysis and monitoring used to make informed decisions that enhance efficiency, quality,
and safety. OI leverages advanced data analytics and visualization tools to track
performance metrics, detect anomalies, and optimize processes across the production
lifecycle. This proactive approach to monitoring not only improves operational efficiency
but also plays a vital role in ensuring Process and Product Quality Assurance (PPQA).

20
 Faculty of Electrical Engineering Technology

By continuously analyzing data from production, OI enables companies to

identify and resolve potential quality issues before they impact final products, thus
aligning closely with PPQA goals. For example, OI can monitor equipment performance
and environmental conditions, both of which are crucial to maintaining consistent product
quality. It also provides insights into deviations or potential bottlenecks, allowing quality
teams to implement corrective actions immediately. As a result, OI supports PPQA by
enhancing visibility, reducing process variability, and ensuring products meet quality
standards. This integration ultimately leads to higher customer satisfaction and
compliance with industry regulations, driving overall operational excellence in the
industry. Figure 2.5 shows an example of OI made for the item which is the application
of Powdered Coating model.

Figure 2.5: Example of an OI

Using the example of the OI above, PPQA department will be able to follow the
steps on how to check the product and determine whether it is a defective or not. Some
of the OI can be applied to different types of models and there are some that utilize
different type of OI to do quality checking.

21
 Faculty of Electrical Engineering Technology

2.6 Parts and Product for PPQA Inspection

PPQA department in Minebea mainly do quality check on each part of a product.
Some of the product have an additional part that need to be considered when doing quality
checking.
2.6.1 Check sheet
In order to differentiate types of items that need to do in OI, check sheet, which
has been prepared by the PPQA manager, will be used. These check sheets have steps,
types of items and the equipment that are related in an organized manner for the employee
to follow and fill up. Created in a fill-it-up form, the check sheet can be easily followed
by referencing OI and guidance from supervisor and other employee. Figures below is an
example for a check sheet that has been filled up and noted with additional notes for
references and tips for each step and items.

Figure 2.6.1: (a) Example of press core assembly check sheet

22
 Faculty of Electrical Engineering Technology

Figure 2.6.1: (b) Example of armature core check sheet

2.6.2 Press 1 and Press 2

In Minebea, the PPQA department separate into 2 types of branches, Press 1 and
Press 2. In this report, the main focus for the branch will be Press 1. However, Press 2
parts will also be touched briefly.
i. Press 1
The parts that are being made in Press 1 is mainly core, frame, plate
bottom, and other metallic base parts. These parts have its own functionality and
mainly being pressed by one type of machine. The machine used for the pressing
and shaping the parts have multiple parts of die that can be assemble and
reassemble by machine technician and machine keeper. These machines will
operate base on the quantity that has been determined by the higher ups. If there
is not enough material to process a certain parts or model, the machine will either
change the model type or be stop and wait for future instruction.

23
 Faculty of Electrical Engineering Technology

Each of these machines will have at least one machine keeper that will
observe and be on look out in case of error. The machine keeper will also do
quality checking of their own as a precaution after running the machine for a
certain amount of time. Once the parts had been produced to a certain degree, the
product will be package and either sent to the production line of the company or
be shipped out to other countries that operates similar like how Minebea
Electronics Motor (M). For example, the country that accept these products are
Thailand, Cambodia, and India branches.
During the internship, the main working inspection that were given are
mainly base on the armature core. There are lots of products and model that need
to be considered even if its within one aspect of the motor. Example of the
products that mainly in production are EPB, Pan14, PWN10, SA/SE/SU/18/24/30
and multiple more.
Each of these models will be assemble with Press 2 parts to create motor
that will be sold globally.

ii. Press 2
As for the Press 2 side, it is mainly focusing on mould-able parts of the
motor. Press 2 uses plastic base to mould the bracket, U-spring, commutator
base, insulators, magnet holder and other more. However, due to limitation of
time, these parts had only been introduced and learned for a short amount of
time.

Thus, by explaining each type of branches and which parts are being made from
Press 1 and Press 2, it gives a better understanding regarding the importance of the
separation of these branches. One reason the decision to make it into 2 press sites is to
allow more freedom and more make it more organizable. Few figures below show the
parts and product from each press.

24
 Faculty of Electrical Engineering Technology

Figure 2.6.2: (a) EPB Armature Core being tested for its internal dimension (ID)

Figure 2.6.2: (b) Press 1 parts in a line

Figure 2.6.2: (c) One of the armature core’s model which is being compared to a finger

25
 Faculty of Electrical Engineering Technology

Figure 2.6.2: (d) Bracket from Press 2 being analysed under Keyence machine

2.7 Equipment for Quality Checking

This section will touch upon the equipment that were used during the internship.
There are various types of equipment that were learned during the internship. With
enough guidance from other co-workers and supervisors, the equipment that were used
running smoothly throughout the internship days.
The equipment used for measuring the model has its own expiry date. The expiry
date is determined by the PPQA employee base on the calibration lifetime. Once the
equipment has expired, the PPQA employee will sent the old equipment to the industrial
maintenance (IM) department for them to readjust and calibrate to its original position.
However, if an error or the equipment is faulty, the equipment will be scrapped and a new
equipment will be ordered to replace the old one. If the equipment has been calibrated, a
new expiry date will be given to the equipment by the PPQA department. The lifespan of
the equipment is 6 months once it has been calibrated. Figures below shows that a green
sticker containing the date of the equipment are pasted on the equipment for the employee
to see the equipment.

26
 Faculty of Electrical Engineering Technology

Figure 2.7: (a) Shows the box full of jigs for measuring frame for PWN10A model

Figure 2.7: (b) shows side by side of two types of measuring jig different in lengths

Figures 2.7: (c) Expiry date are visible from the equipment above

27
 Faculty of Electrical Engineering Technology

The equipment used for each quality check are manually, semi-automatically, and
automatically operated by the employee. By grouping the equipment in each of this
category, it is much easier to approach on how to take into consideration of which
equipment that can be combine or improve for a better production in regard of quality
checking.
2.7.1 Manually operated equipment
Manually operated equipment requires direct physical input from the user
to function, often relying on levers, buttons, or cranks to control and perform
tasks. That means the employee must fully interact with the equipment itself to
get the measurement needed for quality check.
Majority of the equipment that are used in PPQA are a manually operated
equipment. For example, almost all the items that are required to check for
armature core uses Caliper, Micrometer, Pin/Plug Gauge, Push/Pull Gauge, and
Digimatic Indicator. Some of these equipment will be shared among employees
and other departments for their own purpose. Each model will either have
additional items that are required to be checked.
The pic tester figure below is mainly used to measure the shaft deflection
on the samples that has been collected. There will be specification of minimum
and maximum amount of required to be in order to determine the sample is a
defect product. In the figure, a push/pull gauge can be identified. The equipment
is used to measure the strength of the insert core. The equipment in the figure is
specifically to measure EPB.

Figure 2.7.1: (a) Picture of Pic Tester and Push/Pull Gauge

28
 Faculty of Electrical Engineering Technology

The equipment shown in the figure below is called digimatic indicator,

where, the equipment is measuring shaft to core length of the EPB model.
Digimatic indicator have lots of multiple items that measure both armature core
and press core assembly. As for armature core, the equipment is used to measure
the burr height on the cut part of the core. And for EPB model case, digimatic
indicator will be used to measure the warpage of the sample.

Figure 2.7.1: (b) Picture of Digimatic Indicator

The equipment that are shown in the figure below is a calliper. The calliper
is also manually operated where the user has to manually give and input and get
the output of the measurement. The figure below shows the calliper measuring the
armature core outer dimension, using flat jig as a medium, to reduce any possible
error in measuring the model.

29
 Faculty of Electrical Engineering Technology

Figure 2.7.1: (c) Calliper measuring armature core

Microscope is used to see any visual defect and any micro-defect that can
not be seen by the naked eye. Visual defect such as dentation, scratches, and
foreign object will be reflected by the lighting. Meanwhile, micro-defect such as
burr, peeling and excessive oil can be seen using the microscope. If any of the
defect had been seen by employee, it is required to scrap the current sample batch
and take a new one. If there is still a visible defect, the machine will be stopped
and be under maintenance. Figure shown below is the microscope that has been
used in PPQA department. The microscope, similar with the other equipment, will
be shared among employees.

Figure 2.7.1: (d) Microscope as one of the manually operated equipment

30
 Faculty of Electrical Engineering Technology

The pic tester, as mentioned before, will measure the deflection of the
shaft. In this case, the shaft is the metal rod that is positioned in the middle of the
armature. Once the shaft had been inserted into the pressed core, there will be
slight deviation to the original shaft. This, multiplied with the position of internal
dimension of the core deviated to one another, will increase the deflection of the
shaft. Thus, disrupting the rotational speed, torque and frequency of the motor. In
a large scale, this will cause a lot of losses especially the distrust of customer and
for the shareholder. Hence, this is one of the reasons why PPQA are established
and the problem that PPQA need to solve.

Figure 2.7.1: (e) Pic Tester measuring

One of the other equipment that is used to check the diameter of internal
dimension is pin/plug gauge. This gauge is in the shape of shaft and base on its
diameter, will check the fitness of each model’s ID. There are two measurements
needed to be filled in the check sheet, which is, the loose (GO) and the tight
(STOP) measurement. These pin/plug gauge came with different set of sizes from
two to four decimal numbers. Base on the required size of the EPB model, the
figure shows the best gauge for the EPB. However, once the pin has been inserted
to the core, the core will be discarded to avoid mistake in sampling.

31
 Faculty of Electrical Engineering Technology

Figure 2.7.1: (f) Pin/Plug gauge for EPB model

With the example and figure above backing the uses of manually operated
equipment, the overview of PPQA equipment regarding the type of equipment.
This section will be useful for the discussion and improvement that can be made
regarding the quality check and the speed of it.

2.7.2 Semi-automatically operated equipment

Semi-automatically operated equipment combines manual and automated

functions, allowing operators to initiate processes while automation completes
specific tasks. In PPQA, this type of equipment plays a significant role in
balancing human oversight with efficiency and precision in manufacturing. For
instance, an operator might set up the machine and adjust parameters, after which
the equipment performs a sequence of automated steps. This dual functionality
ensures that each product meets quality standards, as operators can monitor and
intervene if adjustments are needed, minimizing defects and variations.

32
 Faculty of Electrical Engineering Technology

Semi-automated equipment also enhances PPQA by standardizing

repetitive processes while giving operators the ability to quickly respond to
quality issues in real time. For example, in industries such as electronics
manufacturing, semi-automated testing equipment allows for fast yet accurate
quality checks, reducing human error and maintaining product consistency. This
setup is especially beneficial for processes requiring a high level of precision,
where automation ensures repeatability, while manual control allows for
adjustments based on real-time observations.
Figures below will show some of the semi-automatically operated with a
brief explaination of the equipment itself. Starting off with tension machine as the
first equipment, this machine utilizing pneumatic to press on the shaft motor while
measuring the force that the motor can handle before the shaft slipped. Figure
2.7.2.1 shows the image of the tension machine that is used for holding strength
test.

Figure 2.7.2.: (a) Tension Machine use to check the strength of armature

33
 Faculty of Electrical Engineering Technology

Measurescope, the equipment that use to measure the lengths of model in

microscopic range, is considered as semi-automatic equipment. This is because
the equipment utilizes the input and control from user to measure the required
items. However, the measurescope have a fax machine that will automatically
print out the measured for the part. Figure below shows the picture of the
measurescope.

Figure 2.7.2: (b) Picture of Measurescope

Besides that, the uses of high accuracy CCD Micrometer are also
considered to be one of the semi-automatic equipment. This equipment measures
the dark part on the light display once the shaft has been placed onto it. This
measurement will be in diameter and the position for the shaft to be measured is
on both side on the end of the shaft and one in the middle of the shaft. This part is
manually positioned by the user.

34
 Faculty of Electrical Engineering Technology

Figure 2.7.2: (c) Figures shows the CCD Micrometer

By using semi-automatically operated equipment, companies achieve

greater control over quality while benefiting from increased productivity and
reduced waste. This approach aligns with PPQA objectives by improving process
reliability, ensuring product quality, and reducing the likelihood of defects.
Overall, it creates an optimized quality assurance process that combines the
strengths of human judgment with the efficiency of automation.

35
 Faculty of Electrical Engineering Technology

2.7.3 Automatically operated equipment

Automatically operated equipment plays a transformative role PPQA by
enabling fully autonomous operations that reduce human intervention and
improve precision. This equipment is designed to perform tasks with minimal to
no manual input, allowing processes to be executed quickly, efficiently, and
consistently. For PPQA, this means that quality control checks can be
standardized across all production stages, significantly reducing the risk of human
error and variability. Automatically operated equipment is ideal for repetitive,
high-precision tasks, ensuring that each product meets defined quality standards
without the need for constant operator oversight.
In PPQA, automatically operated equipment also enhances data accuracy
and provides valuable insights for continuous improvement. Modern automated
systems often come equipped with sensors and data collection capabilities,
allowing real-time monitoring of product specifications and process conditions.
By analyzing this data, companies can detect deviations immediately, address
potential issues proactively, and maintain strict compliance with quality
standards. For example, in industries like automotive manufacturing, automated
testing and inspection equipment can measure precise tolerances in parts, ensuring
every component meets the required specifications before assembly.
During the internship, only one equipment that is usable for the intern to
use that are fully automatic, which is called Keyence Machine. A Keyence
machine refers to various advanced inspection, measurement, and automation
systems produced by Keyence Corporation, a global leader in sensor, vision, and
measurement technology. These machines are commonly used for quality control
and production efficiency in industries such as manufacturing, electronics,
automotive, and healthcare.
Keyence machines offer several capabilities:
• Precision Measurement: Keyence’s measurement systems use
laser sensors, optical comparators, and other tools to measure
dimensions, thickness, and other parameters with high accuracy,
making them ideal for parts inspection and quality assurance.

36
 Faculty of Electrical Engineering Technology

• Automated Inspection: Keyence vision systems and cameras detect

defects, misalignments, or inconsistencies in products, which helps
in maintaining quality standards without manual inspection.
• Data Collection and Analysis: Many Keyence machines are
equipped with data analysis capabilities, allowing operators to
monitor trends, improve production processes, and ensure
consistent quality over time.
• Easy Integration: These systems are designed to be user-friendly
and easily integrated into existing production lines, supporting
various automation needs like robotic integration and real-time
data feedback for immediate adjustments.
With a strong focus on accuracy and efficiency, Keyence machines help
industries maintain high-quality standards, increase productivity, and reduce
inspection times.

Figure 2.7.3: (a) Shows the Keyence Machine measuring armature core deflection

37
 Faculty of Electrical Engineering Technology

Figure 2.7.3: (b) Keyence machine measuring the shearing angle of the EPB armature

Figure 2.7.3: (c) Keyence Machine in home page and measuring EPB bracket

38
 Faculty of Electrical Engineering Technology

Moreover, automatically operated equipment such as Keyence that has

been mentioned above in PPQA contributes to increased productivity and reduced
costs by streamlining quality checks and eliminating delays associated with
manual inspection. This integration of automation allows PPQA department in
Minebea to focus on process optimization and preventive measures rather than
corrective actions, ultimately fostering a culture of continuous quality
improvement. The result is a more efficient quality assurance system that aligns
with industry standards, reduces defect rates, and ensures high customer
satisfaction.

2.8 Armature Core Assembly

The armature core assembly is a crucial component in electric motors and

generators, responsible for generating electromotive force (EMF) through
electromagnetic induction. In a motor, the armature core is typically a stack of thin,
laminated iron sheets, designed to reduce energy losses from eddy currents. The core
houses the armature windings, which are copper coils wound around the core slots. When
current flows through these windings, they interact with the magnetic field of the stator,
creating a force that causes the rotor to spin.
The assembly process of the armature core is complex, involving precise
alignment of the laminations and windings to ensure efficiency and stability. Proper
alignment reduces energy loss and enhances the motor’s performance, as any
misalignment can lead to vibration, overheating, and decreased efficiency. In high-
performance motors, such as those used in automotive or industrial applications, the
armature core assembly is rigorously tested for balance and insulation to withstand high
rotational speeds and heat.
PPQA department plays a key role in overseeing the armature core assembly,
ensuring that each step meets the best quality standards required for optimal motor
performance. In the case of Minebea Electronics Motor (M) Sdn. Bhd., the Press 1
division, responsible for the armature core assembly, is closely monitored by PPQA to
maintain consistency, efficiency, and product reliability.

39
 Faculty of Electrical Engineering Technology

Quality assurance for the armature core assembly focuses on several critical areas,
including lamination alignment, winding accuracy, and insulation integrity. PPQA
oversees these aspects by collecting samples and by following the part production quality
assurance check sheet. These are implemented throughout the assembly process to detect
any misalignment, imbalanced winding, or insulation weaknesses or any defects or
deviations from specifications can lead to performance issues such as vibration, noise, or
overheating, which would compromise the motor’s lifespan and efficiency. By enforcing
rigorous testing and quality control protocols, PPQA ensures that the armature core meets
operational standards and customer requirements.
For better communication between the two division, PPQA also works with Press
1 to gather and analyze data on assembly performance, allowing for trend analysis and
continuous improvement. This collaboration helps identify areas where automated
inspection tools or additional training could enhance quality consistency. By leveraging
both real-time inspections and data analysis, PPQA supports Press 1 in reducing defect
rates, optimizing the assembly process, and ensuring that every armature core meets
Minebea’s high standards for durability and performance.

2.9 Overview of this chapter

As an overview of what has been reported, this chapter has provided an in-depth
overview of the industrial training projects and activities conducted during internship at
Minebea Electronics Motor (M) Sdn. Bhd. The projects and tasks assigned across various
departments, particularly in the Process and Product Quality Assurance (PPQA) unit and
Press 1, allowed the application of academic knowledge in a real-world setting, further
developing the technical skills and understanding of quality management in
manufacturing. This chapter outlined the hands-on experiences that has been gained, from
monitoring the armature core assembly process to ensuring quality control measures were
met at every stage. These activities not only broadened the perspective on production
workflows but also underscored the importance of precision, automation, and continuous
improvement in maintaining high-quality standards.
The skills and insights acquired from these projects have been instrumental in
shaping of the understanding of quality assurance and operational efficiency, providing a
solid foundation for future roles in the industry.

40
 Faculty of Electrical Engineering Technology

CHAPTER 3 DISCUSSION AND RECOMMENDATION

3.1 Introduction

The following section provides an analysis of current practices within the PPQA
department at Minebea. This discussion identifies the key areas for improvement to
enhance the effectiveness and efficiency of PPQA operations. Building on the company’s
commitment to high-quality manufacturing, the recommendations are outlined to address
challenges related to automation, data management, employee training, and cross-
departmental collaboration. By implementing these strategies, can further strengthen its
quality assurance processes, reduce inefficiencies, and uphold the rigorous quality
standards expected by both the company and its global clientele.

3.2 Discussion

The PPQA department at Minebea, plays a pivotal role in ensuring that the
company's products meet the best of quality standards. As part of MinebeaMitsumi, Inc.,
the PPQA department is held to high standards, particularly in precision and reliability,
which are essential for the manufacturing of motors and electronic components used
globally.
However, there are several areas where improvements could enhance the
department's efficiency, accuracy, and adaptability to meet increasing market demands.
One key area of improvement is automation in quality control processes. While Minebea
has invested in advanced technology, further integration of automated inspection systems,
such as Keyence machines, could enhance the consistency of product checks and reduce
the time needed for manual inspections. Keyence machines, with their advanced
measurement and defect detection capabilities, can streamline quality assurance by
providing precise, real-time data on product dimensions and consistency. This automation
would allow operators to focus on higher-level tasks, thereby improving productivity
while maintaining quality standards.

41
 Faculty of Electrical Engineering Technology

Another area for improvement is data integration and analysis. Currently, the
PPQA department likely collects a vast amount of data on production quality, but it may
not be fully utilized for predictive analysis and continuous improvement. Implementing
advanced analytics software or platforms for tracking and analyzing this data would
enable the department to identify trends, predict potential issues, and take proactive
measures to avoid defects. The strategy to utilizes software or platforms to track the defect
can also ease the workload of employee and PPQA team as well. This would be
particularly valuable in identifying recurrent quality issues and could facilitate improved
training for employees in quality-critical tasks.
Additionally, training and skill development for PPQA employees could further
enhance quality outcomes. Given the rapid advancements in technology and inspection
systems, staff training on the latest inspection equipment and data analysis tools is
essential. Regular workshops on quality control best practices, coupled with up-to-date
training on equipment such as automated inspection machines, would empower staff to
maximize their use of available technology. By introducing a new technology that capable
in reducing the burden the employees, this will make a good working environment for the
employees themselves. However, the employees must be given a full training in operating
the technologies itself. In this way, the PPQA department could build a workforce that is
adaptable and highly skilled, ensuring that the company maintains its reputation for
quality.
In summary, the analysis of the PPQA department at highlights several areas for
potential improvement to support the company’s commitment to quality and efficiency.
While the department operates with a strong foundation in quality assurance, there is an
opportunity to further enhance its processes through greater automation, advanced data
analysis, and targeted training programs. Implementing these changes would not only
reduce errors and increase productivity but also enable the PPQA department to respond
more proactively to quality issues. By focusing on these strategic improvements, Minebea
can uphold its high standards and contribute to the overall operational excellence that
MinebeaMitsumi Inc. values across its global operations.

42
 Faculty of Electrical Engineering Technology

3.3 Recommendations

The following recommendations outline strategic initiatives to enhance the PPQA

department at Minebea. These proposals focus on increasing automation, strengthening
data analysis capabilities, and advancing employee skill development. By implementing
these improvements, the PPQA department can better support the company’s high
standards of quality and precision, reduce inefficiencies, and create a more proactive
approach to quality control. These recommendations aim to reinforce Minebea’s
reputation for excellence in manufacturing and align with the overarching quality
objectives of MinebeaMitsumi Inc.
One of the recommendations that can be made is by investing in additional
automated inspection equipment. By expanding the use of Keyence machines or similar
equipment to automate more stages of the quality control process. This investment would
reduce human error and increase the speed of inspections.
Besides that, enhancing the data analysis capabilities using software is also one of
these recommendations. The implementation of advanced data analytics software can
utilize quality control data more effectively. This could include predictive maintenance,
trend analysis, and anomaly detection, providing the PPQA department with actionable
insights to improve product quality.
In addition to previous recommendation, by doing a regular training program to
the employees of PPQA department, it can increase the productivity in quality checking.
By developing a continuous learning programs focused on quality assurance technology
and best practices. Training employees on using advanced inspection tools and data
analysis platforms will improve both productivity and quality outcomes.
Moreover, the implementation of cross-departmental quality feedback loops can
establish a structured feedback mechanisms between production and PPQA department.
This can address and resolve the quality issues in real-time, encouraging collaboration
and improving the responsiveness to potential quality concerns.
By addressing these areas, the PPQA department at Minebea Electronics Motor
(M) Sdn. Bhd. can strengthen its quality control processes, optimize resource use, and
maintain the high standards expected by MinebeaMitsumi Inc.

43
 Faculty of Electrical Engineering Technology

CHAPTER 4 CONCLUSION

The internship at Minebea Electronics Motor (M) Sdn. Bhd., a branch of

MinebeaMitsumi Inc., has been an invaluable experience. This internship had been
offering practical exposure and deep insights into the applications of Process and Product
Quality Assurance (PPQA) in a real-world setting. Throughout this internship, the
application and knowledge that had been gathered during the study years in Universiti
Malaysia Perlis has been able to be utilized efficiently. Furthermore, this internship had
also increase in developing student’s technical skills, and gained a first-hand experience
with industry-standard practices, including quality control and operational efficiency
measures. Observing the implementation of advanced technologies such as semi-
automated and automated equipment in the PPQA department broadened my
understanding of quality management and its critical role in maintaining product
standards.
Additionally, the experience underscored the importance of continuous
improvement and proactive quality management within a global organization. I gained
insights into opportunities for future enhancements, such as further in studying in the
aspect of automation, data integration, and enhanced training. This could streamline the
operations and strengthen the quality assurance efforts in a future employment. This
internship has provided a solid foundation in both technical and professional skills, as
well as reinforcing my commitment to upholding quality standards and continuous
learning in my future career.

44
 Faculty of Electrical Engineering Technology

REFERENCES

(i) Information from the www (internet)

[1] Basic Information. Minebea Electronics Motor (Malaysia) Sdn. Bhd..

(n.d.).https://www.wesleyconnect.com/listingpage/my/Minebea-Electronics-Motor-
Malaysia-Sdn-Bhd

[2] Working at Minebea Electronics Motor (Malaysia) Sdn Bhd - company Profile &
Information. Working at Minebea Electronics Motor (Malaysia) Sdn Bhd - Company
Profile & Information - Ricebowl.my. (n.d.).
https://www.ricebowl.my/company/minebea-electronics-motor-malaysia-sdn-bhd

(ii) Personal Communications

[1] Puan Nasriah Nasir. Personal communications, Human Resources Department of

Minebea Electronics Motor (M) Sdn. Bhd.
[2] Puan Ruslina Abu Yaziz. Personal communications, Manager of PPQA Department
of Minebea Electronics Motor (M) Sdn. Bhd.

45
 Faculty of Electrical Engineering Technology

APPENDICES

Appendix A: Host Company Evaluation Form

46
 Faculty of Electrical Engineering Technology

Appendix B: Intra Verification Form

47
Faculty of Electrical Engineering Technology

48