INDUSTRIAL TRAINING REPORT
MUHAMMAD IMRAN BIN AHMAD
BACHELOR OF ENGINEERING
(ELECTRICAL ENGINEERING)
FACULTY OF ELECTRICAL ENGINEERING
TECHNOLOGY
UNIVERSITI MALAYSIA PERLIS
2024
I
INDUSTRIAL TRAINING REPORT
(EMK 40112)
Host Company:
Marelli Automotive
Lighting Malaysia SDN BHD.
Taman Perindustrian, PMT 723, PERSIARAN
CASSIA SELATAN 1,TAMAN
PERINDUSTRIAN BATU KAWAN, 14110
SIMPANG AMPAT, PULAU
PINANG, MALAYSIA.
NAME : MUHAMMAD IMRAN BIN
AHMAD
MATRIC NO: 201291095
PROGRAM : UR6522002- INDUSTRIAL POWER
SESSION : 2023/2024
II
UNIVERSITI MALAYSIA PERLIS
DECLARATION OF REPORT
Author’s Full Name : MUHAMMAD IMRAN BIN AHMAD
Host Company : MARELLI AUTOMOTIVELIGHTING MALAYSIA SDN
BHD.
(Industrial Training)
Date of Industrial : 25 March 2024 – 8 September 2024
Training
Academic Session : 2023/2024
I hereby declare that this report becomes the property of Universiti Malaysia Perlis(UniMAP)
and to be placed at the library of UniMAP. This report is classified as:
CONFIDENTIAL (Contains confidential information under the Official
Secret Act 1997)*
RESTRICTED (Contains restricted information as specified by the
organization where research was done)*
✓ OPEN ACCESS I agree that my report to be published as online open
access (Full Text)
I, the author, give permission to reproduce this report in whole or in part for the purpose of
research or academic exchange only (except during the period of years, if so
requested above)
Certified by:
SIGNATURE SIGNATURE OF SUPERVISOR
MUHAMMAD NAJMI BIN MD
YUSSOF
(NEW IC NO. /PASSPORT NO.) NAME OF SUPERVISOR
Date: 6 September 2024 Date: 6 September 2024
NOTES : * If the thesis is CONFIDENTIAL or RESTRICTED, please attach with the letter from the
organization with the period and reasons for confidentiality or restriction. Replace thesis with dissertation
(MSc by Mixed Mode) or with report (coursework)
I
ACKNOWLEDGMENT
Alhamdulillah. I am deeply grateful to Allah the Almighty for His blessings, which have enabled me
to successfully complete both my industrial training and the accompanying report within the given
timeframe.
I would also like to express my heartfelt gratitude and love to my family, who have continually
supported and stood by me throughout this journey. Without their unwavering support, I would not be
where I am today.
Additionally, I consider myself fortunate to have had the opportunity to be an intern at Marelli
Automotive Lighting Malaysia Sdn. Bhd. This experience provided me with invaluable learning
opportunities, allowing me to adapt to new situations and gain the professional development essential
for success in the industry. I am truly grateful to the company for offering me this placement.
During my internship, I met many wonderful people and professionals who generously shared their
knowledge and expertise with me. I would like to extend my deepest gratitude to Mr. Muhammad
Najmi Md Yusoff, my company supervisor, who warmly welcomed me, guided me, and encouraged
me throughout my industrial training.
I also want to thank my parents, siblings, and friends for their immeasurable support and motivation,
which helped drive me to complete this internship. Additionally, I am thankful for the cooperation and
support from my colleagues, as well as my fellow students who interned at Marelli Automotive
Lighting Malaysia Sdn. Bhd. Your contributions, whether direct or indirect, played a significant role
in my successful completion of this internship.
Finally, I would like to extend my sincere thanks to my university, Universiti Malaysia Perlis
(UniMAP), for providing this exceptional six-month internship program.
May Allah SWT bless you all.
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TABLE OF CONTENTS
PAGE
DECLARATION OF REPORT i
ACKNOWLEDGMENT ii
LIST OF TABLES v
LIST OF FIGURES vi
LIST OF ABBREVIATIONS vii
LIST OF SYMBOLS viii
ABSTRAK ix
ABSTRACT x
CHAPTER 1 INTRODUCTION 1
1.1 Chapter Overview 1
1.2 Introduction 1
1.3 Objective 2
CHAPTER 2 COMPANY BACKGROUND 3
2.1 Introduction 3
2.2 About Company 3
2.3 Company Location 4
2.4 Background History 4
2.5 Vision and Mission 5
2.5.1 Vision 5
2.5.2 Mission 5
2.6 Company Organization Structure 6
2.6.1 MALM Pre-Production Organization 7
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2.7 Summary 8
CHAPTER 3 TRAINING SCOPE 9
3.1 Introduction 9
3.2 Pre-production Department 9
3.2.1 Lens Hard Coating (LHC) 10
3.2.2 Antifog Coating (AFC) 11
3.3 Project During Internship 11
3.3.1 Carbon Fiber Fixture Improvement 11
3.3.2 31UX Appearance Change Metalizing Feasibilities Study 12
3.3.3 Revisit Mangrove Cultivation Project 14
3.4 Summary 16
CHAPTER 4 DISCUSSION & CONCLUSION 17
4.1 Introduction 17
4.2 Discussion 17
4.3 Summary 18
4.4 Recommendation 19
4
LIST OF TABLES
NO. PAGE
5
LIST OF FIGURES
NO. PAGE
2.1 Marelli Corporate Logo 3
2.2 MALM location 4
2.3 MALM Organization Chart 6
2.4 Pre-Production Team Organization Chart 7
3.1 Polycarbonate (PC) granules 9
3.2 RJ01 Outer lens 10
3.3 Lens Hard Coating (LHC) Process flow 10
3.4 Fish-eye defects 11
3.5 Steel and Carbon Fiber fixtures 12
3.6 Old model for 31ux 13
3.7 New model for 31ux 2024 study 13
3.8 Revisit Mangrove Cultivation Project 15
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LIST OF ABBREVIATIONS
vii
LIST OF SYMBOLS
viii
ABSTRAK
Laporan latihan industri direka bentuk untuk mendokumentasikan dan merenung pengalaman
dan pengetahuan yang diperoleh semasa latihan di Marelli Automotive Lighting Malaysia
Sdn. Bhd., terletak di Batu Kawan, Pulau Pinang. Latihan amali ini berlangsung dari 25 Mac
2024, hingga 8 September 2024, yang menjangkau 24 minggu, dan merupakan keperluan
untuk menamatkan program Sarjana Muda Teknologi Kejuruteraan Elektrik (Kuasa Industri)
tahun keempat. Laporan ini memberikan gambaran menyeluruh tentang aktiviti yang
dilakukan semasa latihan. Dalam tempoh ini, pelajar telah ditugaskan ke bahagian Salutan
Keras Lacquer dan Salutan Antifog dalam Jabatan Pra-pengeluaran. Tugasan ini menawarkan
pandangan yang berharga tentang proses dan memberikan pengetahuan mendalam berkaitan
pencahayaan automotif. Matlamat utama latihan industri ini adalah untuk membangunkan
disiplin, kemahiran, kerja berpasukan, dan pengetahuan teknikal dalam persekitaran yang
selamat dan sesuai. Laporan ini disusun kepada empat bahagian utama: Pengenalan, Profil
Syarikat, Skop Latihan dan Kesimpulan. Setiap bahagian menawarkan penjelasan terperinci
tentang projek, aktiviti, dan tanggungjawab yang dijalankan semasa latihan industri.
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ABSTRACT
The industrial training report is designed to document and reflect on the experiences and
knowledge gained during an internship at Marelli Automotive Lighting Malaysia Sdn. Bhd.,
located in Batu Kawan, Pulau Pinang. This internship took place from March 25, 2024, to
September 8, 2024, spanning 24 weeks, and was a requirement for completing the fourth
year of the Bachelor of Electrical Engineering Technology (Industrial Power) program. The
report provides a comprehensive overview of the activities performed during the internship.
During this period, the student was assigned to the Lacquer Hard Coating and Antifog
Coating sections within the Pre-production Department. This assignment offered valuable
insights into the processes and provided in-depth knowledge related to automotive lighting.
The primary goal of this industrial training was to develop discipline, skills, teamwork, and
technical knowledge in a secure and appropriate environment. The report is organized into
four main sections: Introduction, Company Profile, Training Scope, and Conclusion. Each
section offers a detailed explanation of the projects, activities, and responsibilities
undertaken during the industrial training.
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CHAPTER 1
INTRODUCTION
1.1 Chapter Overview
This chapter provides an overview of the industrial training that was conducted,
detailing key aspects such as the training period, objectives, placement, activities, and
outcomes of the internship program. It serves as a comprehensive briefing on the
industrial training experience, offering insights into the duration of the program, the goals
that were set, the specific placement within the industry, the activities undertaken during
the internship, and the results achieved through the program.
1.2 Introduction
Industrial Training (INTRA) is a crucial requirement for engineering students at
Universiti Malaysia Perlis (UniMAP) to graduate. This program is mandatory based on
the course of study, as it ensures students are well-prepared for real-world jobs and can
adapt to professional environments. The primary purpose of industrial training is
to immerse students in industry settings, allowing them to gain first-hand experience
in working environments. Through this exposure, students enhance their communication,
leadership, and technical skills, along with other essential abilities.
The objectives of INTRA include fostering student engagement with industry,
introducing them to industrial culture and real working environments, increasing
the competitiveness and marketability of graduates, and building a strong relationship
between UniMAP and the industry.
The training spans 24 weeks, during which students are assigned to specific
departments within a company. They are required to complete tasks assigned by their
company supervisor. At the end of the internship, students are evaluated by both
a university panel and the company supervisor, based on their coursework and the tasks
they have completed during their industrial training.
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1.3 Objective
The objectives of this projects are :
1. The Industrial Training course provides students with the invaluable
opportunity to apply the theoretical knowledge acquired during their academic
study to real-world engineering projects and address practical challenges.
2. By actively participating in a wide range of projects under the mentorships of
experienced professionals, engineering students can significantly enhance their
technical skills and expertise.
3. The program also fosters the establishment of professional networks, enabling
students to engage with engineers, managers, and other industry professionals,
thereby expanding their connections in the field.
4. As students tackle real engineering tasks and successfully contribute to projects,
they gain self-assurance in their abilities and experience a boot in self-esteem,
motivating them to excel in their chosen career paths
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CHAPTER 2
COMPANY BACKGROUND
2.1 Introduction
This chapter will provide a detailed description of the company where the student
completed their industrial training. It will cover several key areas, including the
organization’s structure, the top management team, and the corporate profile.
Additionally, it will outline the specific tasks assigned to the student and the roles they
played within the company. This section aims to give a comprehensive understanding of
the company’s operations and the student’s involvement during the training period.
2.2 About Company
Marelli is one of the world’s leading global independent suppliers to the
automotive sector. With a strong and established track record in innovation and
manufacturing excellence, Marelli mission is to transform the future of mobility through
working with customers and partners to create a safer, greener and better-connected
world. With around 43,585 employees worldwide, the Marelli footprint includes
170 facilities and R&D centres across Asia, the Americas, Europe, and Africa, generating
revenues of 1,606 billion JPY (10.573 billion EUR) in 2023. The companies’ success is
built on manufacturing excellence (Monozukuri) and innovation (Genba). Monozukuri
refers to the creation of value in all respects, through manufacturing fine products and
providing excellent services in a timely manner, to meet customers’ expectations. Genba
refers to the workplace, in which clues for innovation can always be found.The company
logo and detail are as shown in Figure 2.1 and Figure 2.2.
Figure 2.1 : Marelli Corporate Logo
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2.3 Company Location
Marelli Automotive Lighting Malaysia Sdn Bhd (MALM) is located at Batu
Kawan Industrial Park in Simpang Empat, Pulau Pinang, Malaysia. This industrial park
near Second Penang Bridge, Jambatan Sultan Abdul Halim Muadzam Shah. It is also a
very strategic lo as it is located near North-South Expressway which connects North and
East of Malaysia. Company location address: PMT723, Persiaran Cassia Selatan 1,
TamanPerindustrian Batu Kawan, Mukim 13, 14110 Seberang Perai Selatan, Malaysia
Figure 2.2 : MALM location.
2.4 Background History
Automotive Lighting (AL) was born in 1999 as an equally shared joint venture between
German Bosch and Italian Magneti Marelli. AL is a global leader in exterior automotive
lighting in the field of components and systems. One year later, in 2000, Robert Bosch and
Magneti Marelli reached an agreement whose result was the acquisition of the
majority of Automotive Lighting share by the Italian components maker Magneti Marelli.
At the same time Magneti acquired SEIMA GROUP (Headquarters in Tomezzo, Italy), a
global leader in rear lamps manufacturing, whose share were then conferred
to Automotive Lighting. With the acquisition of the Seima Group, Magneti Marelli owns
majority of AL shares. As a result of these mergers and acquisitions, AL is presently the
second biggest company in the world in external automotive lighting business, with strong
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domestic market in Europe and expanding bases in Asia, North America and South
America. Automotive Lighting is a global supplier for all major car makers. 7 In Malaysia,
Marelli Automotive Lighting Malaysia SDN BHD known as MALM (previously known
as ALMA) which is extend for Marelli Automotive Lighting Malaysia Sd. Bhd. MALM is
a manufacturer of external lights and its products consist of cars lighting system such as
headlamp, rear lights and auxiliary lamps. This company provided the product to local and
International Company. PROTON and PERODUA are main local customers. Other than
local customers, MALM also has international market, mainly in Japan. MAZDA, ISUZU,
HONDA and SUZUKI are among the companies that are dealing with MALM. Their
products are exported to China, Europe, America and Southeast Asia.
2.5 Vision and Mission
2.5.1 Vision
We exist to innovate and transform the future of mobility.
2.5.2 Mission
We work hand-in-hand with our customers to create a safer, greener
and better-connected world..
2.6 Company Organization Structure
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Figure 2.3 : MALM Organization Chart
2.6.1 MALM Organization
Figure 2.4 below illustrates the organizational structure of the Pre-production
within theTechnology Department. This organizational chart provides a detailed view of
thedepartmental hierarchy, showcasing the various roles and relationships within the
team.
Figure 2.4 : Pre-Production Team Organization Chart
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2.7 Summary
In a summary, this chapter provides a detailed overview of Marelli Automotive
Lighting Malaysia is part of Marelli, a global leader in automotive components.
Established through the merger of Calsonic Kansei and Magneti Marelli, the company
combines Italian and Japanese expertise to deliver innovative automotive lighting
solutions. With a focus on manufacturing excellence and continuous innovation, Marelli
Automotive Lighting Malaysia plays a key role in supporting the global automotive
industry, contributing to safer and more efficient vehicle lighting systems. Additionally,
it details the hierarchies within specific departments such as Pre-production Department,
illustrating the roles and responsibilities of managers, engineers, and interns within these
units.
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CHAPTER 3
TRAINING SCOPE
3.1 Introduction
As a manufacturing Engineer, achieving several key objectives is crucial for
ensuring optimal performance and continuous process improvement. First, it is essential
to gain acomprehensive understanding of the sub-processes involved in Hard Coating and
Antifog processes, including machine parameters and process flow.
Effective problem-solving skills are necessary to address and resolve issues
related to both Hard Coating and Antifog processes. This involves identifying root causes
and implementing appropriate solutions.
3.2 Pre-production departments
Preproduction is a department of in transforming raw materials into parts. In lens molding
section, raw material known as polycarbonate (PC) granules will be heated up and
injected into mold by thermoplastic hydraulic machine. Shows in figure 3.1 is PC granule
raw material and Figure 3.2 shows Outer lens after received heating and molding.
Figure 3.1: polycarbonate (PC) granules
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Figure 3.2: RJ01 Outer lens
Mold in the thermoplastic machine will give shape to the liquefied PC and thus, PC lenses
are made. These lenses will undergo LHC and AFC process to further enhance its durability,
cosmetic appearance and clarity.
3.2.1 Lens Hard Coating (LHC)
Figure 3.3: RJ01 Outer lens
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Lens hard coating is a process where polycarbonate lenses undergo chemical coating process
mainly made up from lacquer to make it scratch resistant, maintains clarity and provide more
durable UV protection. This process will make the lenses increase in its longevity and provide
more value to vehicles.
3.2.2 Antifog Coating (AFC)
Anti-fog coating is to prevent headlamp from fogging up inside. Usually, moisture is present in the
headlamp and when the light is turned on, the humid air inside condensates. The exterior of the lens
is cooler than the interior, so the moisture adheres to the inside of the lens. This causes condensation
in your headlights. AFC process prevents this event from occurring with the coating that has been
applied to the lens.
3.3 Project During Internship
3.3.1 Carbon Fiber Fixture Improvement
Existing Honda T00 fixtures have deformations that enable lacquer in LHC process
penetrates inside area of the lenses. This occurrence made fish-eye defects from forming.
Figure 3.4: Fish-eye defects
To reduce these defects, improvements have been made by Process Engineer, Mr Najmi by
replacing the steel fixtures with carbon fiber fixtures.
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Figure 3.5: Steel and Carbon Fiber fixtures
The new carbon fiber fixture, designed to hold lenses securely, has a minimal opening
between the fixture and the lens when the lens is loaded. This tight fit, while ensuring
stability, may pose challenges during the loading and unloading process, potentially leading
to alignment issues or even damage to the lens. It may be necessary to assess the fixture
design to determine if slight adjustments to the opening could improve the ease of use without
compromising the fixture's stability or the lens's integrity. These carbon fiber fixtures were
delivered in batches by vendor, DRB-HICOM Defence Technologies Sdn Bhd. These carbon fiber
fixtures need to be inspected for their quality, quantity and condition. All this information must be
recorded to track the delivery status and condition after hours of usage during production.
Maintenance of these new fixtures need to be modified from existing steel fixtures as the materials
used are different. During the early stages of using these new fixtures, everything needs to be recorded
and saved to provide improvement information to DEFTECH for further fixtures enhancement.
3.3.2 31UX Appearance Change Metalizing Feasibilities Study
The study focused on assessing various aspects, including production capabilities, cost-
effectiveness, and potential market demand. Key areas of consideration included the
adaptation of existing manufacturing processes to accommodate the new model, the
integration of innovative technologies, and the alignment of the 31UX model with current
industry standards and customer expectations. The feasibility study aimed to identify
potential challenges and opportunities, ensuring that the 31UX model could be successfully
launched and sustained in the competitive market. Shown in figure 3.5 is the old model for
31ux and figure 3.6 shown for new feasibility for 2024.
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Figure 3.6: Old model for 31ux
Figure 3.7: New model for 31ux 2024 study
metalizing process for the 31UX model, it's crucial to cover the unrequested parts with
precision, leaving a 2mm space to allow for outgassing. This space ensures that any gases
released during the process can escape, preventing defects or imperfections in the coating.
Proper coverage and spacing are essential to maintain the integrity of the unrequested parts
while achieving a high-quality finish on the metalized sections.
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3.3.3 Revisit Mangrove Cultivation Project
The HR department has long embraced the practice of assigning each batch or year of
interns a significant project to manage independently, fostering teamwork, leadership, and
practical experience. Past projects have ranged from organizing Charity Week, where interns
coordinated various charitable events and fundraising activities, to executing Recycling Day,
which involved raising awareness about sustainability and environmental responsibility.
These projects are designed to challenge the interns, giving them real-world experience in
planning, organizing, and executing initiatives that have a positive impact on the community
and environment.
For the current batch of interns, the HR department has tasked them with carrying out the
“Revisit Mangrove Cultivation Project,” scheduled for the 11th of July 2024, at Pusat
Pendidikan Kecil Hutan Paya Laut in Nibong Tebal. This project holds particular
significance as it involves revisiting a previous environmental initiative— the mangrove
plantation project that was initially launched on the 8th of October 2022. The goal of this
revisit is to observe the progress of the mangroves that were planted during the original
project, assess their growth and health, and understand the impact they have had on the local
ecosystem over the past two years.
In addition to the physical aspect of revisiting the plantation, this project also serves an
educational purpose. The interns will have the opportunity to engage in learning sessions
about the importance of mangroves to our ecosystem. These sessions will cover the critical
role mangroves play in coastal protection, preventing soil erosion, supporting biodiversity,
and acting as natural carbon sinks that help mitigate the effects of climate change.
By learning about these aspects, the interns will gain a deeper understanding of why
conserving and expanding mangrove forests is vital not only for local communities but also
for the global environment.
The “Revisit Mangrove Cultivation Project” is designed to be more than just a visit; it is
an immersive experience that encourages the interns to reflect on the long-term impact of
environmental projects and the importance of sustainability. By taking responsibility for this
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project, the interns will develop a range of skills, from project management and teamwork to
environmental stewardship and public engagement. This project is a continuation of the HR
department's commitment to providing meaningful, hands-on learning opportunities that
prepare interns for future challenges, both in their careers and as responsible global citizens.
Figure 3.8: Revisit Mangrove Cultivation Project
As the assigned photographer and videographer for the “Revisit Mangrove Cultivation
Project,” the role involves meticulously documenting the event to highlight its significance
and outcomes.
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3.4 Summary
Chapter 3 provides a comprehensive examination of the training scope, offering a
detailed account of the activities undertaken during the internship. This chapter focuses
on the specific tasks and experiences gained throughout the training period. Key
outcomes and insights from the training are discussed, with a more in-depth analysis and
interpretation of these findings to be presented in Chapter 4.
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CHAPTER 4
DISCUSSION & CONCLUSION
4.1 Introduction
This chapter contain the conclusion and conclusion of the industrial training
activities with the finding and benefit obtained. On this chapter also can be write
suggestion or recommendation to improve the industrial training program in the future.
4.2 Discussion
During the 24 weeks of industrial training at Malaysia Automotive Lighting
Malaysia SDN BHD, I gained invaluable experiences and insights that extended
beyond the academic knowledge from my Electric Industrial Power course at
university. The practical exposure offered unique lessons, knowledge, and skills that
are challenging to acquire in a purely academic setting.
One key lesson was the importance of effective communication in the work
environment. Clear and open communication is essential to prevent
misunderstandings, conflicts, and delays. The adage "if you're shy to ask, you will get
lost; if you refuse to paddle, your boat will drift away" underscores the necessity of
seeking clarification when unsure about a process. Building strong relationships and
maintaining good communication with colleagues are crucial for resolving issues and
ensuring project success.
Additionally, the training highlighted the significance of effective time and
work management. Proper planning and organization were vital in making tasks more
manageable and ensuring efficient progress. Maintaining detailed records of essential
data proved useful for future reference and troubleshooting any problems that
emerged.
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Overall, the industrial training provided practical experiences that enriched
my understanding of the engineering field, emphasizing skills and practices that
complement and extend beyond academic learning.
4.3 Summary
In conclusion, the 24 weeks of industrial training at Malaysia Automotive
Lighting Malaysia SDN BHD effectively met and exceeded the established objectives.
This period provided a valuable opportunity to apply theoretical knowledge acquired
during academic studies to real-world engineering scenarios. By engaging in a diverse
range of projects, the student addressed practical challenges and gained substantial hands-
on experience in engineering tasks.
Under the guidance of experienced professionals, the students actively
participated in various projects, which significantly enhanced their technical skills and
expertise. This involvement in engineering processes not only deepened the student's
understanding of industry practices but also facilitated the practical application of
academic concepts.
The training program also played a pivotal role in developing professional
networks. Through interactions with engineers, managers, and other industry
professionals, the student expanded their connections within the field—an invaluable
asset for future career opportunities and professional growth.
Additionally, working on real engineering tasks and contributing to meaningful
projects greatly boosted the student's self-confidence and self-esteem. Confidenceased
confidence has been crucial in motivating the student to excel in their chosen career path
and pursue further success in the engineering field.
Overall, the industrial training at Malaysia Automotive Lighting Malaysia SDN
BHD provided a comprehensive and enriching experience that not only met but surpassed
the training objectives, effectively preparing the student for a successful career in
engineering.
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4.4 Recommendation
In my opinion, Malaysia Automotive Lighting Malaysia SDN BHD is an excellent place for
internship students to complete their training. Most of the people I met there were friendly
and hardworking. They provided guidance and support to all interns, even when the tasks
were unfamiliar. Their assistance was thorough, ensuring that students understood their
responsibilities. This supportive environment offered valuable experiences and served as a
positive role model, helping students adapt naturally to the work environment and learn more
about their job roles.
The 6-month duration of the internship was sufficient for students to gain substantial
experience and potentially secure permanent job opportunities. However, I hope that
the industrial training management at UniMAP can develop a more organized schedule to
better facilitate the internship process for students.
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