JUNE 2024

JTM Processing Tempering (First Solar Heat Strengthened S6+1) post-assessment FY2024
Please fill in your full name.
SAFWAN NORMAL
Name: Shift:

Employee ID: 1001

1. Based on the customer requirements, we have included 3 type of control limit in our production
process control, USL/LSL, UCL/LCL & AUCL/ALCL. Please fill in the blank below based on
these 3 types of control limit in the diagram below: (3 marks)
Berdasarkan keperluan pelanggan, kami telah memasukkan 3 jenis had kawalan dalam kawalan
proses pengeluaran kami, USL/LSL, UCL/LCL & AUCL/ALCL. Sila isi tempat kosong
berdasarkan 3 jenis had kawalan ini dalam rajah di bawah:

USL/LSL UCL/LCL AUCL/ALCL

(CUSTOM (JTM (PROCESS
ER SPEC) CONTROL CONTROL
LIMIT) LIMIT)

2. List down the customer specifications limit, internal specifications limit and adjustment
control limit of the following parameter:
(11 marks)
Senaraikan spesifikasi keperluan pelanggan, spesifikasi dalaman dan had kawalan pelarasan untuk
parameter berikut:
CUSTOMER INTERNAL ADJUSTMENT
PARAMETER SPECIFICATION SPECIFICATION CONTROL LIMIT
LIMIT ± LIMIT ± ±
Length 2016 +- 0.8mm 2016 +- 0.5mm 2016 +- 0.3mm
Width 1216 +- 0.8mm 1216 +- 0.5mm 1216 +- 0.3mm
Hole diameter 1 & 2 20.5 +- 1mm 20.5 +- 0.5mm 20.5 +- 0.5mm
Hole location x1 & x2 883 +- 1mm 883 +- 0.5mm 883 +- 0.3mm
Hole location y1 & y2 165.5 +- 1mm 165.5 +- 0.5mm 165.5 +- 0.3mm
Diagonal 2354.3 +- 1.1mm 2354.3 +- 1.1mm 2354.3 +- 1.1mm
Thickness 2.2 +- 0.1mm 2.2 +- 0.1mm 2.2 +- 0.1mm
Corner dub 2.5 +- 1mm 2.5 +- 0.5mm 2.5 +- 0.5mm
Roller wave 0 ~ 250 mD 0 ~ 200 mD 0 ~ 200 mD
Edge kink 0 ~ 0.25 mm 0 ~ 0.20 mD 0 ~ 0.20mD
Surface stress 7500 +- 1500 psi 7500 +- 1000 psi 7500 +- 1000 psi
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3. Based on your answer above, kindly state the function of the adjustment control limit in our
process. (2 marks)
Berdasarkan jawapan anda di atas, sila nyatakan fungsi had kawalan pelarasan dalam proses
kami. 1. to reduce internal reject 2. to reduce variation between upper and lower specification
3. to increase CPK 4. To ensure the SPC line plot in control limit
…………………………………………………………………………………………………………………

…………………………………………………………………………………………………………………

4. Fill in the blank for the control chart below based on the 3 specifications & control limits. (3marks)

Isikan tempat kosong untuk carta kawalan di bawah berdasarkan 3 spesifikasi dan had kawalan

CONTROL CHART

upper USL Customer Spec

UCL Jinjing Spec

Auxiliary Control limit/

Adjustment control
limit AUCL/ALCL

LCL Jinjing Spec

lower LSL Customer Spec

5. The most important parameter for S6+1 is hole which includes the existence of 2 holes, hole diameter,
and hole location. One of the checking methods we use during the final inspection process is the POKA
YOKE hole check, please specify the original function for this POKA YOKE hole check. (2 marks)

Parameter yang paling penting untuk S6+1 ialah lubang yang merangkumi kewujudan 2 lubang, diameter
lubang, dan lokasi lubang. Salah satu kaedah semakan yang kami gunakan semasa proses pemeriksaan
akhir ialah semakan lubang POKA YOKE, sila nyatakan fungsi asal untuk semakan lubang POKA YOKE
ini.
To check the hole through after drilling. if not through or uncomplete drilling, the rod unable
to go through. The hole position should be check at XY table.
…………………………………………………………………………………………………………………

…………………………………………………………………………………………………………………
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6. In the Product Quality Control Plan, the surface separator powder process was done by the
machine powdering at the final packing stage. Based on the latest NCP issuance in May, briefly
describe the updated corrective action practice that must be done if we found the surface with no
separator powder. (4marks)

Dalam Pelan Kawalan Kualiti Produk, proses serbuk pemisah permukaan dilakukan dengan
serbuk mesin pada peringkat pembungkusan akhir. Berdasarkan terbitan NCP terbaharu pada
bulan Mei, huraikan secara ringkas amalan tindakan pembetulan yang dikemas kini yang mesti
dilakukan jika kita mendapati permukaan tanpa serbuk pemisah.
1. Inform Sv and technician to stop the line. Record all the information of the rack detail
……………………………………………………………………………………………………
2. Open NCP if more than 20pcs, then give to SV.
……………………………………………………………………………………………………
3. Te affected glass cannot be manual powder but need to slot in to machine again for auto powder by
machine powder
……………………………………………………………………………………………………
4. Record the new rack number into NCP
……………………………………………………………………………………………………

7. The surface scratches is the most important defect that cannot simply been released without go
through the judgment based on the product defect standard set by the customer. Briefly state the:
(3marks)
Calar permukaan adalah kecacatan paling penting yang tidak boleh dilepaskan begitu sahaja
tanpa melalui pertimbangan berdasarkan piawaian kecacatan produk yang ditetapkan oleh
pelanggan. Nyatakan secara ringkas:
40mm
a. Allowance length of light scratches (mm): ………………………………………………...
40cm
b. Allowance total collective length of light scratches (cm): …………………………………
120cm
c. Allowance of minimum separation between collective scratches (cm): ……………………
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8. Apart from the dimensions of the product, there are still some cosmetic requirements of the
product that we need to meet the criteria set by the customer. For the cosmetic defect images listed
below, please define the name of the defect. (12marks)

Insect trap in between glass Tape stick at surface/tape mark Sample marking not clean
……………………………. …………………………. …………………………………

Abnormal roller wave/Bow DIG

Surface Overgrind
……………………………. ……………………………. …………………………….

Surface overgrind that

change the corner dub pre chip at edge LOG/edge Undergrind
……………………………. ……………………………. …………………………….
shape

Inconsistent corner dub Small+ OK No corner dub Burnmark at corner dub

……………………………. ……………………………. …………………………….
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9.

Based on the image above during XY Table Sampling & verification inspection, as a QA technician
what action should you take at the SAMPLING STAGE & FINAL PACKING STAGE for the
dimension that is out of the specifications. (4marks)

Berdasarkan imej di atas semasa Persampelan Jadual XY & pemeriksaan pengesahan, sebagai
juruteknik QA apakah tindakan yang perlu anda ambil di PERINGKAT PERSAMPELAN &
PERINGKAT PEMBUNGKUSAN AKHIR untuk dimensi yang di luar spesifikasi.
1. Inform deman to STOP machine immediately ! send verify glass Main and Sub for buy off.
………………………………………………………………………………………………………………
2. Send information of the reject to PIC packing for NCP issuance
………………………………………………………………………………………………………………
3. Production need to sorting the glass. after sorting if they want to use, need to verify 100% at XY table
………………………………………………………………………………………………………………
4. Update the sorting result information into NCP
………………………………………………………………………………………………………………
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10. At the XY Table sampling & verification inspection, the QA team found from Production Line
3, that the reading difference of the length dimensions for the main-machine & sub-machine is
large, and the main-machine control is at the minimum specs. & the sub-machine control at the
maximum specs. Based on this situation, what may affect the final packing stage, and as a QA
technician responsible for sampling inspection what action should you take to avoid the problem
on the visual inspection at the final packing stage? (4marks)

Pada pemeriksaan persampelan & pengesahan Jadual XY, pasukan QA mendapati daripada
Barisan Pengeluaran 3, bahawa perbezaan bacaan dimensi panjang untuk mesin utama & sub-
mesin adalah besar, dan kawalan mesin utama berada pada spesifikasi minimum. & kawalan
sub-mesin pada spesifikasi maksimum. Berdasarkan situasi ini, apakah yang boleh menjejaskan
peringkat pembungkusan akhir, dan sebagai juruteknik QA yang bertanggungjawab untuk
pemeriksaan pensampelan apakah tindakan yang perlu anda ambil untuk mengelakkan masalah
pada pemeriksaan visual pada peringkat pembungkusan akhir?
At packing we will found a cosmetic issue which is the length will be up and down
………………………………………………………………………………………………………………
immediately inform QA in process and deman to adjust back the main and sub line to
………………………………………………………………………………………………………………
nominal so that the CPK and the final product will be same height because customer dont
like to see abnormal when receiving the glass. they will curious and send feedback to
………………………………………………………………………………………………………………
engineer.
………………………………………………………………………………………………………………

………………………………………………………………………………………………………………

11. State the specification weight of the glass separator powder (2marks)

Nyatakan berat spesifikasi serbuk pemisah kaca.

350 +- 50 mg
……………………………………………………………………………………………………
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12. Based on image below, please list the requirements for the KMT1 & KMT2 final packaging
condition before it can be released with the QC PASSED Label for FG Warehouse. (20 marks)

Berdasarkan gambar di bawah, sila senaraikan keperluan untuk keadaan pembungkusan akhir
KMT1 & KMT2 sebelum ia boleh dikeluarkan dengan Label LULUS QC untuk Gudang FG.

Tin Side label no glass debris inside buckle holder

1…………………………………………………. 6………………………………………………….
Strap in good condition no plastic damage
2…………………………………………………. 7………………………………………………….
Buckle in good condition Tape in good condition
3…………………………………………………. 8………………………………………………….
Bolt and nut tighten Ok Glass angle
4…………………………………………………. 9………………………………………………….
Metal rack base leg not bend Wooden bar in good condition
5…………………………………………………. 10………………………………………………….
Silica Gel qty
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13. Based on image below, please list the requirements for the DMT2 final packaging condition
before it can be released with the QC PASSED Label for FG Warehouse. (18 marks)

Berdasarkan gambar di bawah, sila senaraikan keperluan untuk keadaan pembungkusan akhir
DMT2 sebelum ia boleh dikeluarkan dengan Label LULUS QC untuk Gudang FG.

Figure 2.0

JTM logo Metal strap in good condition

1…………………………………………………. 6………………………………………………….
green strap in good condition Plastic no damage
2…………………………………………………. 7………………………………………………….
No nail at wooden bar silica gel qty
3…………………………………………………. 8………………………………………………….
Complete qty rubber pad Tin side label
4…………………………………………………. 9………………………………………………….
bottom plate have gap to check CD Side metal plate (hanging with cabel)
5…………………………………………………. 10………………………………………………….

14. Please state the glass quantity per rack that we supply to the customer. (2marks)
Sila nyatakan kuantiti kaca setiap rak yang kami bekalkan kepada pelanggan
195pcs 10 box/container
a. KMT1 & KMT2: ………………………….
185pcs 10 box/container
b. DMT2: ……………………………………
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15. At the final packing stage, in our production process practices, if there were a corner dub that
is under-grind, the production packing team are required to perform the rework to ensure the corner
dub dimension meet the customer specifications. However, if there is a rework process happened,
there will be a glass debris on the glass surface, as a QA technician, what action should you take
to ensure the glass debris is not left on the glass surface. (2marks)
Pada peringkat pembungkusan akhir, dalam amalan proses pengeluaran kami, jika terdapat alih
suara sudut yang kurang dikisar, pasukan pembungkusan pengeluaran dikehendaki melakukan
kerja semula untuk memastikan dimensi alih suara sudut memenuhi spesifikasi pelanggan.
Walau bagaimanapun, jika terdapat proses kerja semula berlaku, akan terdapat serpihan kaca
pada permukaan kaca, sebagai juruteknik QA, apakah tindakan yang perlu anda ambil untuk
memastikan serpihan kaca tidak tertinggal di permukaan kaca
.
Ask the packing to clean the debris by blow with airgun or wipe with clean cloth. if not, inform Prod SV
........................................................................................................................................................
 JUNE 2024

16. The non-conformance product report must be issued to the production team if we found a
non-conformity in the production line. Briefly state the general criteria set by the QA department
for the NCP issuance & the purpose and importance of the NCP issuance. (5marks)
Laporan produk ketidakpatuhan mesti dikeluarkan kepada pasukan pengeluaran jika
kami mendapati ketidakpatuhan dalam barisan pengeluaran. Nyatakan secara ringkas
kriteria umum yang ditetapkan oleh jabatan QA untuk pengeluaran NCP & tujuan serta
kepentingan pengeluaran NCP.
If production handover to QA, we found >20pcs, then need to open NCP. if not, ask them to segregate
……………………………………………………………………………………………………
and rework again.

……………………………………………………………………………………………………
If rework more than 2-3 time, inform prod SV, if happen again, open NCP
……………………………………………………………………………………………………
NCP is to save our life, to make sure the NCP escape to customer and as a evidence saying that we
……………………………………………………………………………………………………
found the reject base on spec and if someone want to release, it takes the responsibility.

……………………………………………………………………………………………………

17. State the price of 1 piece of our glass that we sell to the customer in MYR. (1mark)

Nyatakan harga 1 keping gelas kami yang kami jual kepada pelanggan dalam MYR.

MYR30
……………………………………………………………………………………………………………..

18. Our customers require the company to comply with the ISO9001 quality management system
(QMS) standards. The external auditor will conduct an annual ISO9001 audit every December.
Please state the controlled document the auditor uses as a reference during the audit. (2marks)
Pelanggan kami memerlukan syarikat untuk mematuhi piawaian sistem pengurusan kualiti (QMS)
ISO9001. Juruaudit luar akan menjalankan audit tahunan ISO9001 setiap Disember. Sila
nyatakan dokumen terkawal yang digunakan oleh juruaudit sebagai rujukan semasa audit.
Control Plan
………………………………………………………………………………………………………………..