INDUSTRIAL TRAINING FULL REPORT new.pdf

September 7, 2017 | Author: Elora Sofea | Category: Internal Combustion Engine, Axle, Engines, Machines, Vehicle Parts
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INDUSTRIAL TRAINING REPORT JABATAN KERJA RAYA CAWANGAN KEJURUTERAAN MEKANIKAL PANJI, 16100, KOTA BHARU, KELANTAN DARUL NAIM.

NUR ELORA SOFEA BINTI ZURAIMAN MA 13174 FACULTY OF MECHANICAL ENGINEERING UNIVERSITY MALAYSIA PAHANG

27 JUNE 2016 - 2 SEPTEMBER 2016

ACKNOWLEDGEMENT

In the Name of Allah, the Most Beneficent, the Most Merciful. All praised to the Prophet Muhammad SAW. Firstly, thankful to Allah SWT for gave me this great chance to go through industrial training in Jabatan Kerja Raya (JKR) and finish it successfully. First and foremost, I would like to thank my industrial supervisor, Abd Malek Bin Abd Ghapar for guidance, information and knowledge during completing my training in JKR. Besides from that, I also want to thank all the head units, Mr Zainuddin (heavy machinery), Mr Fadhli (light vehicle), Mr Anuar (VTL) during my training in heavy machinery, vehicle and VTL for their guidance, knowledge and support. Apart from that, I also want to convey gratitude to all the staffs and technicians here for their kindness in helping me while completing my industrial training. In addition, it is important to have teamwork during my training and here I really want to thank my colleagues for their kindness, exchange ideas and knowledge during my training even though we came from different universities. Then, I want to convey my appreciation to my Universiti Malaysia Pahang lecturers and supervisor, Mr Rosdi bin Daud for his willingness to come to JKR Kelantan. Last but not least, I want to thank my family for their love, motivation and support during my industrial training in JKR. Thanks for all the ideas, opinion, knowledge and suggestion that have given to me in order for me to complete this report.

i

ABSTRACT

This report is set out to give the reader full information about my industrial training in Jabatan Kerja Raya (JKR) Mechanical Branched in Kelantan. Industrial training is one of the compulsory curriculums in Universiti Malaysia Pahang which students need to complete whether in consultant, factory and company. This course is sets up for student in order to give them experience and gain knowledge in working environment before going through the real working life. My industrial training is at Jabatan Kerja Raya or known as JKR Mechanical branched which provide maintenance and construction to the public sectors in Malaysia. In Jabatan Kerja Raya, I have been send to Mechanical branched which located in Panji, Kota Bharu, Kelantan. At this branched, I have been assigned to workshop, building maintenance and project. In workshop, there are three units which are heavy machinery, vehicle and Vehicle Testing Line (VTL). During my placement, I have learned a lot new knowledge about vehicle maintenance and safety. These knowledge are useful for me in future and gives me a lot of advantageous to prepare myself for my future career. Last but not least, in this report included the introduction, brief background about this company, task and mini project I have been assigned, recommendations and conclusion in details during my industrial training in JKR.

ii

TABLE OF CONTENTS

Page ACKNOWLEDGEMENTS

i

ABSTRACT

ii

TABLE OF CONTENTS

iii

LIST OF FIGURES

CHAPTER 1

v

COMPANY PROFILE

1.1

Company Background

1

1.2

Company’s Objective

1

1.2.1 Vision

2

1.2.2 Mission

2

Logo

3

1.3.1 Description

3

1.3.2 Colour

3

Organization Chart

4

1.4.1 JKR Main Branch Organization Chart

4

1.4.2 JKR Mechanical Branch Organization Chart

5

1.3

1.4

1.5

1.4.2.1 Project Department

6

1.4.2.2 Administration and Financial

7

1.4.2.3 Workshop Department (Light and Heavy Vehicle)

8

Gantt Chart (Industrial Training)

CHAPTER 2

2.1

9

COMPANY ACTIVITIES

Introduction

10

2.1.1 Workshop Department

10

2.1.2 Project Department

11

2.1.3 Building Maintenance

11

2.1.4 Administration and Financial

11

iii

CHAPTER 3

STUDENT ACTIVITIES

3.1

Engine overhauled

12

3.2

Final Drive (Heavy Vehicle)

18

3.2.1 Final Drive Mechanism

19

3.2.2 Types of Final Drive

20

3.2.3 Types of Heavy Machinery

20

3.3

Vehicle Test Line (VTL)

22

3.4

Project/ Tasks

29

3.4.1 Oil Trap Water Separator

29

3.4.2 Workshop Layout Renovation

31

3.4.3 Oil Drum Storage

32

Summary of Daily Activities

40

3.5

CHAPTER 4

CONCLUSION

4.1

Conclusion

47

4.2

Recommendations

48

49

REFERENCES

iv

LIST OF FIGURES

Figure No.

Title

Page

1.1

JKR’s Logo

3

1.2

Organizational Chart

4

1.3

Mechanical Branch

5

1.4

Project Unit

6

2.1

Administration and Financial

7

2.2

Workshop Department

8

2.3

Heavy Vehicle

9

2.4

Vertical Engine

13

2.5

Horizontal Engine

13

2.6

Horizontal Opposed Engine

13

2.7

‘V’ 8 Engine

14

2.8

Rotary Engine

14

3.1

Light Vehicle

16

3.2

Piston

17

3.3

Assembling

18

3.4

Final Drive Drawing

19

3.5

Planetary gear

20

3.6

Excavator

21

3.7

Bulldozer

22

3.8

Test lane

23

v

3.9

Vehicle Entry

24

3.10

Above Carriage Suspension

24

3.11

Database

25

3.12

Diesel Smoke Tester

25

3.13

Smoke Testing

26

3.14

Side Slip Test (Front Wheel)

26

3.15

Roller Brake Test (Rear Wheel)

27

3.16

Undercarriage Test

28

3.17

Test Report

28

3.18

Drainage Before

29

3.19

Insert Grill

30

3.20

Insert Sand

30

3.21

Insert Mat

31

3.22

Workshop Layout

32

3.23

Full View

33

3.24

Front View

34

3.25

Side View

34

3.26

Side View (3D)

35

3.27

Top View (3D)

35

3.28

Back View

36

3.29

Side View (3D)

36

3.30

Back View (3D)

37

3.31

Side View

37

3.32

Top View

38

3.33

Side View

39

vi

3.34

Zoomed View

39

3.35

Side View

40

3.36

Gear

41

3.37

Workshop Layout

42

3.38

Oil Jet (Sketch)

45

vii

CHAPTER 1 INTRODUCTION OF INDUSTRIAL TRAINING

1.1 COMPANY BACKGROUND

Jabatan Kerja Raya or Public Works Department as it known has been formed since 100 years ago by Major J.F.A McNair as its first head organization. JKR is the federal government department in Malaysia under Ministry of Works Malaysia (MOW) which is responsible for construction and maintenance of public infrastructure in Malaysia. Meanwhile in Sabah and Sarawak another entity of Public Works Department exists under respective state government’s jurisdiction. As public government department, JKR has touched many aspects of the nation's life by providing necessary infrastructure, such as roads and water supply systems. With this, JKR has been divided into a few branched which experts in their own field such as mechanical, building, road, slope, electrical, military and water works. The mains infrastructure of public government which maintained by JKR are federal road, state road, public hospitals, public school and public government buildings. For this training, I have been assigned to Mechanical branched in Panji, Kota Bharu, Kelantan. In Mechanical branched, works are focused on machinery maintenance and mechanical construction for the department. 1.2 COMPANY’S OBJECTIVE 1. Complete the mechanical systems design work that meet the standards, quality, time and cost as prescribed. 2. Deliver mechanical system / projects that meet quality, time and cost as prescribed. 3. Perform maintenance of mechanical systems, vehicles, plant construction and quarry plant belonging to the government that meet quality, time and cost as prescribed. 1

4. Manage the assets of which consist of mechanical services in buildings, vehicles, plant and quarry belonging to the PWD to meet the current department needs. 5. Provide technical consultancy related to the mechanical engineering field to government agencies and statutory bodies within time required. 1.2.1 Vision To become a world-class service provider and centre of excellence in asset management, project management and engineering services for the development of the nation’s infrastructure through creative and innovative human capital and state-of-the-art technology. 1.2.2 Mission PWD Mechanical Engineering Branch is committed to contribute to national development by: 

Helping our customers realize the policy / objectives and deliver services through cooperation as a strategic partner.



Standardisation of processes and systems to provide consistent revenue.



Providing asset management services and the effective and innovative projects.



Strengthen existing engineering competency.



Developing human capital and new competencies.



Emphasis on integrity in providing services.



Building a harmonious relationship with the community.



Preserving the environment in service delivery.

2

1.3 LOGO

Figure 1.1 Logo

1.3.1 Description: 1. Generally, the exhibited logo as it mirrors the diversity of fields of work entrusted to the Jabatan Kerja Raya (JKR). 2. Starting from the base, black colored curved lines symbolizes clean water supply and reflects that JKR is a dynamic organization. 3. The arch-shaped lines in concentrated black color denotes to construction related work and maintenance of bridges and as well as a representative of the JKR organizations assigned as one of the leading the country in implementing engineering work. 4. Straight black lines, on the line shaped arch symbolize the participation to implement the road network nationwide. 5. Fourteen lines on a straight line signify a pledge to executing building operations comprising 14 states and federal territories in Malaysia. 1.3.2 Colour 1. Yellow symbolizes maturity brands of JKR as one of the oldest organizations established and replicates the image growing in achieving its objectives. 2. Black symbolizes strength / unity quality of branch - the branch in JKR organization entrusted to implementing development projects. 3. Grey symbolizes existence values - values of human capital in provide services.

3

1.4 ORGANIZATION CHART 1.4.1 JKR Main Branch Organization Chart Organization chart below show the main departments in the JKR Kelantan. There are eight departments in JKR Kelantan. Each department play their role in maintaining and developing country infrastructures. For instance, in JKR Mechanical Branched works are mainly focused in machinery maintenance and mechanical construction.

Figure 1.2 Organizational Charts

4

1.4.2 JKR Mechanical Branch Organization Chart

Figure 1.3 Mechanical Branch

5

Mechanical Branch has been divided into five department 

Project



Building maintenance



Administration and Financial



Quarry



Workshop (Light And Heavy Vehicle)

Each of the department play an important role in maintaining goverment machinery and infrastructure. 1.4.2.1 Project Department

Figure 1.4 Project Unit

6

1.4.2.2 Administration and Financial

Figure 2.1 Administrational and Financial

7

1.4.2.3 Workshop Department (Light and Heavy Vehicle)

Figure 2.2 Workshop department

Workshop department is divided into three units which are Light Vehicle, Heavy Machinery/Vehicle and Vehicle Test Line (VTL). Function of Light Vehicle and Heavy Machinery units are kind of similar. It needs to maintain and repair the government light and heavy vehicle. In Light Vehicle unit, it provides transportation for staff to go to construction site while Heavy Machinery unit provides vehicle for construction like backhoe, bulldozer and etc.

8

1.5 GANTT CHART (INDUSTRIAL TRAINING) 2016 WEEK 1

2

3

4

UNIT HEAVY MACHINERY - Observation - Practical - Operating equipment/ software - Mini project VEHICLE - Observation - Practical - Operating equipment/ software - Mini project VTL - Observation - Data collecting/ analysing - Writing report MAINTENANCE - Site visit - Observation - Data collecting/ analysing PROJECT - Site visit - Data collecting/ analysing - Observation 9

5

6

7

8

9

10

CHAPTER 2

COMPANY ACTIVITIES

2.1 INTRODUCTION In this chapter, I will explain in details about this company activities. As I have explained above that, this company has five department which is Project, Building Maintenance, Workshop, Quarry and Administration and Financial. However, for 10 weeks of internship, I only have been to Workshop, Project and Building Maintenance departments. 2.1.1 Workshop Department

Figure 2.1 Heavy Vehicle

10

Workshop department is divided into three units which is Light Vehicle, Heavy Machinery/Vehicle and Vehicle Testing Line.

Each unit responsible in maintenance or

repairing government vehicle. In Light Vehicle Unit, government vehicle or transportation that need to be repair will be send to this unit. During my internship in this unit, I have watched an engine overhauled and through this I learned more about each compartment in vehicle.

While during heavy

machinery, I have watched demonstration on Final Drive. Besides, for Vehicle Test Line (VTL), I have watched inspection of vehicle. Every government vehicle need to be test to ensure its safety. It need to go through four stages. Stage 1: Vehicle Entry, Above Carriage Inspection Stage 2: Diesel Smoke Test, Emission Test, Sound Level Test And Headlight Beam Test. Stage 3: Sideslip Test, Roller Brake Test, Suspension Test, Speedometer Test. Stage 4: Under Carriage Inspection And End Of Lane Test. 2.1.2 Project Department 

Carry out work in compliance with the government policies which is will be introduced from time to time.



Gives technical advice related to mechanical system tools in government building.



Planning, prepare project draft and estimated cost of mechanical system tools for government building and infrastructure that will build.



Design and prepare drawing with technical specification to call the deal for federation and state project .



Evaluate and accrediated the deal chosen.

2.1.3 Building Maintenance 

Gives technical advice related to mechanical system tools in government building.



Managing and maintaining mechanical system tools of government infrastructures like fire fighting system, elevator and air conditioning system.



Make sure internal energy used in optimal level.



Plan maintenance programme and cost estimated for mechanical system tools in government building and infrastructure which needed to be maintain 11

2.1.4 Administration and Financial Administration and Financial is the main department in JKR Mechanical as it needs to managing and handle expenditure as well as projects in JKR Mechanical. It has been divided into few units like project, mailing, financial and etc.

12

CHAPTER 3

STUDENT ACTIVITIES

3.1 ENGINE OVERHAULED An engine or motor is a machine designed to convert one form of energy into mechanical energy. Heat engines, including internal combustion engines and external combustion engines (such as steam engines), burn a fuel to create heat, which then creates a force. Electric motors convert electrical energy into mechanical motion; pneumatic motors use compressed air and others—such as clockwork motors in wind-up toys—use elastic energy. There are two types of engine system, four stroke engine and two stroke engine and five types of engine which is commonly used 

Vertical



Horizontal



Horizontal opposed



‘V’ 8



Rotary.

13

Figure 2.4 Vertical Engine

Figure 2.5 Horizontal Engine

Figure 2.6 Horizontal Opposed Engine 14

Figure 2.7 ‘V’ 8 Engine

Figure 2.8 Rotary Engine Engine system consists of Mechanical system, Fuel system, Lubrication system, Cooling system, Electrical system. i.

Mechanical system 1. Engine block

8. Main bearing

2. Crankshaft

9. Connecting rod bearing

3. Piston

10. Push rod

4. Cylinder head

11. Tappet

5. Valve

12. Crankcase

6. Piston ring

13. Rocker cover

7. Rocker arm 15

ii.

Fuel system Function: To distribute fuel into combustion chamber with specific amount at a certain time. Component:

iii.

1. Injection pump

7. Throttle body

2. Injector (nozzle)

8. Carburettor

3. A/C pump (transfer pump)

9. Contact point

4. Glow plug (Heater)

10. Distributor

5. Fuel tank

11. Fuel filter

6. Fuel tank cap

12. Spark plug

Lubrication system Function: 1. To avoid engine components from wear 2. Gives lubrication to components during using the engine 3. To control engine temperature Component: 1. Oil sump (crankcase)

4. Oil filter

2. Oil pump

5. Air cleaner

3. Oil gelory iv.

Cooling system There are two system in cooling system which are water cooling system and air cooling system. Function: to control engine’s temperature during using the engine, thus to prevent engine from over heating. Component: 1. Radiator

2. Water pump 16

3. Radiator cap

6. Belting

4. Rubber hose

7. Reserve tank

5. Fan

v.

Electrical system Function: to distribute electrical current to each section with specific amount . Component: 1. Battery

5. Ignition switch

2. Starter motor

6. Fuse box

3. Alternator 4. Relay

After knowing all the components in the engine, we will proceed to engine overhaul. An engine overhaul is a comprehensive engine tune-up that involves removing and disassembling a vehicle's engine, testing all the components, cleaning and replacing parts as needed and then reassembling the engine. This is done to improve vehicle performance and prolong the life of the engine. Why engine need to be overhaul? The factors of engine need to be overhaul are noise in engine, component in engine break and engine under power.

17 Vehicle Figure 3.1 Light

Steps On Engine Disassemble. 

Step 1: Body engine 1. Open bolt/nut round that connected with speed gear 2. Open bolt/nut/screw on engine mounting. 3. Disassemble radiator and its component. 4. Open exhaust manifold and other components which attach to engine body.



Step 2: Engine 1. Clean outer parts of the engine. 2. Throw away the engine oil from the drain plug. 3. Open cylinder head. Start from side part. 4. Open the crankcase and bolt connecting rod. 5. Remove piston by using wooden hammer. 6. Open bolt main cup to remove the crankshaft. 7. Remove camshaft, push rod and tapped. 8. Open bolt fly wheel and remove it housing. 9. Then, open the bolt rocker arm and remove its valve. 10. Remove main bearing in engine block and main cap 11. After that, open ‘C’ clip/eyer clip of guindy pin in piston to remove connecting rod from piston. 12. Remove cylinder head gasket on surface of engine block and clean it. 13. Take out all other remain components and clean them.

Figure 3.2 Piston 18

Figure 3.3 Assembling

Note: Damaged or wear components need to be replace with new component.

3.2 FINAL DRIVE (HEAVY VEHICLE) Final drive is the last part of a set of gears that delivers the necessary torque to turn the wheels of a vehicle. It connects to the differential axle which connects to the wheels. The final drives are located at the ends of each axle housing. Each final drive has the same components. A final drive provides the last speed reduction and the torque increase in the power train. The final drive is a double reduction unit that consists of two planetary gear sets.

19

Figure 3.4 Final Drive Drawing From the figure above; 1. bearing cup and cone 2. bearing cup and cone 3. hub 4. planetary gears 5. ring gear 6. planetary carrier 7. planetary gears 8. planetary carrier 9. sun gear 10. spindle housing 11. wheel 12. sun gear

20

3.2.1 Final Drive Mechanism Ring gear is splined to hub which is connected to spindle housing by spline. Spline housing is fastened to the axle housing. Ring gear, hub and spindle housing are held stationary. The axle shaft is connected to the differential by splines. Sun gear is connected to the axle shaft by splines. Sun gear is engaged with planetary gear. Planetary carrier is fastened to sun gear by spline. Sun gear is engaged with planetary gears which are held in planetary carrier. Carrier is connected to wheel. Power from differential turns the axle shaft. The axle shaft turns gear. Sun gear turns planetary gear because ring gear is stationary, the planetary gear moves around the inside of ring gear. The movement of the planetary gears causes planetary carrier to turn. The planetary carrier is turned in the same direction as sun gear but at a slower speed. Carrier turns sun gear. Sun gear turns planetary gears. Because ring gear is held stationary, the planetary gears move around inside of ring gear. The movement of the planetary gear causes planetary carrier to turn. Carrier is turned in the same direction as sun gear but at a slower speed. Carrier turns wheel. Each final drive has an oil reservoir. Oil is added to the final drive through a filler plug on the outside cover. Oil is removed from the final drive through a drain plug. The components of the final drive are lubricated from the oil that is inside of the final drives. The oil in the final drives is the same oil that is in the differentials. 3.2.2 Types of Final Drive There are different final drive used by heavy machinery which is single reduction, double reduction and planetary gear set. Final drive single and double reduction is rarely used now because of its construction. While final drive using planetary gear widely used in heavy machinery cause it has a lot of advantages.

21

Figure 3.5 Planetary Gear

3.2.3 Types of Heavy Machinery Final drives are widely used in heavy machinery. Heavy machinery is categorized by working methods like excavation, lifting, transportation and mixer. Excavator

Figure 3.6 Excavator

Excavators are used in many ways: 

Digging of trenches, holes, foundations



Material handling



Brush cutting with hydraulic attachments 22



Forestry work



Forestry mulching



Demolition



General grading/landscaping



Mining, especially, but not only open-pit mining



River dredging



Driving piles, in conjunction with a pile driver



Drilling shafts for footings and rock blasting, by use of an auger or hydraulic drill attachment



Snow removal with snow plow and snow blower attachments avator

Bulldozer

Figure 3.7 Bulldozer A bulldozer is a crawler (continuous tracked tractor) equipped with a substantial metal plate (known as a blade) used to push large quantities of soil, sand, rubble, or other such material during construction or conversion work and typically equipped at the rear with a claw-like device (known as a ripper) to loosen densely compacted materials. Bulldozers can be found on a wide range of sites, mines and quarries, military bases, heavy industry factories, engineering projects and farms.

23

3.3 VEHICLE TEST LINE (VTL) Jabatan Kerja Raya mostly inspected government vehicle to ensure its safety. Vehicle test line can do the inspection for few vehicles in short amount of time. Every inspection stages are automatic. Test lane computer (TLC) and sensor in test lane VLT will supervise every vehicle (every axle) on test lane automatically. Passage on test lane is based on big monitors at right side of test lane. At the end of inspection, results will be printed for each vehicle inspected and it will be kept in database for future use.

Figure 3.8 Test Lane

24

Before start the operation, make sure that there is no vehicle and any sensor is switch on on the test lane. There are four stages of inspection 

Stage 1 o Vehicle entry

Figure 3.9 Vehicle Entry o Above carriage inspection

Figure 3.10 Above Carriage Inspection Then, the vehicle data need to be put into the database. The technician need to check the engine and chassis number to ensure it is the same with the database.

25

Figure 3.11 Database 

Stage 2 o Diesel smoke test The test is during engine in neutral / free gear. Diesel smoke tester machine is used to test the pollution emitted by vehicle. If the results are above 50%, the vehicle will be sued to environmental department and need to change its component.

Figure 3.12 Diesel Smoke Tester

26

Figure 3.13 Smoke Testing o Emission test o Sound level test o Headlight beam test For emission, sound level and headlight beam test, it would not be carried out during vehicle test. 

Stage 3 o Side slip test

Figure 3.14 Side Slip Test (Front Wheel)

27

Sideslip test is carried out to inspect the alignment of the car. It will be done for front and back wheel. o Roller brake test

Figure 3.15 Roller Brake Test (Rear Wheel) A roller brake tester is a method of allowing the dynamic assessment of the braking system of a motor vehicle, whilst the vehicle itself is in a static condition. Roller brake testers consist of a mechanical floor unit which contains electrical motors, two independent sets of three measuring rollers, brake force transducers and additional safety sensors. The driving rollers operate at a low (known) speed using a gearbox and motor arrangement and during a test measurements of the maximum braking force are taken by applying the vehicle brakes which induces a reaction force on the electric motor itself. An electric transducer with strain gauges then measures the individual induced forces which are acting during the deceleration phase in order to calculate the individual braking forces for each wheel. o Suspension test o Speedometer test Suspension and speedometer test are not carried out during the inspection. 28



Stage 4 o Undercarriage test

Figure 3.16 Undercarriage Test The undercarriage test is carried out to check if there is any leaking or damaged component. o End of lane; test report

Figure 3.17 Test Report

29

The test report will be out at the end of tests to show the results of the test. The test failed if the results are below the assigned efficiency. For the vehicle that didn’t pass the test, it needs to be send for services. 3.4 PROJECTS/ TASKS 3.4.1

Oil Trap Water Separator.

Firstly, this project given by my supervisor for the trainee as there was visit by HQ Audit. This project is mainly about environmental problem and how the trainee need to came up with solution. Problem Statement: The oil trap in the drainage didn’t properly function as it needs to trap the oil flow from the workshop. This is because the existing oil trap is lower than water flow which cause sand in oil trap cannot trap the oil. Thus, the drainage would be clogged oil. Solution: As this was only a simple task, we came up with solution that the oil trap needs to be build higher than water flow.

Figure 3.18 Drainage (Before) 30

Installation steps:

Figure 3.19 Insert Grill 

The grill is installed in order to hold the mat and sand.

Figure 3.20 Insert Sand

31



Sand is put into the drainage to trap the oil

Figure 3.21 Insert Mat 

Green mat function as to prevent the sand from flowing out

3.4.2

Workshop layout renovation

This task was given to trainees as there was visit by HQ Audit. The workshop of Light and Vehicle Unit need to be renovates to make sure that vehicles, tools, oil drum and others are neatly arranged. I was assigned to sketch the workshop layout and came with new idea for new arrangement. The new layout was drawn by using software Catia by one of our teammates.

32

Figure 3.22 Workshop Layout



Main Office (Pejabat Utama) o For technician and assistant engineer.



Heavy Machinery Main Control Room (Bilik Kawalan Jentera) o For workers to observe works in workshop.



Vehicle Service (Tempat Servis Kenderaan) o Space for repairing and services.



Stor o Install used battery and oil.



Worktable (Meja Kerja) o Space to keep tools and machine.



Toilet (Tandas) o For worker uses



Walkway (Laluan Pejalan Kaki) o Walkway for workers around workshop

33

3.4.3

Oil drum storage

Problem statement: There is no specific space for oil drum storage in workshop. Oil drums are kept scattered at the workshop and it could cause danger for the worker. With this, trainees were given task to build (proposal) for oil drum storage. This project is mainly on environmental working condition. Its objective is to improve working environment, avoid hazard at work like explosion and easy installation of oil drum. Advantages of oil drum storage; 

Easy arrangement. o Oil drum will be neatly arranged if there is storage to keep it. Usually, these drums will be labelled and storing it by label will make work easy.



Improve safety at working place. o If there is oil spill, it will hazardous for workers as it could cause accidents. Thus, by keeping oil drum in storage and guard it well, it will reduce accidents.

Design of oil drum storage by using Inventor AutoDesk

Figure 3.23 Full View

34

Figure 3.24 Front view

Figure 3.25 Side view

35

Figure 3.26 Side view (3D)

Figure 3.27 Top view (3D)

36

Figure 3.28 Back view

Figure 3.29 Side view (3D)

37

Figure 3.30 Back view (3D)

Figure 3.31 Side view

Oil Storage and Layout of workshop using Delmia software. By using the Delmia software, we have designed the possible layout involving the oil trap building and nearest building involved. From all the view that we have chosen, we can see workers gathering the oil barrels to the oil storage building.

38

Oil Storage Workers picking up oil Barrel

Workshop building

Figure 3.32 Top View

39

Workshop Building

Figure 3.33 Side view Oil Trap Building

Figure 3.34 Zoomed view Workers

Workers controller

40

Figure 3.35 Side view

41

3.5 SUMMARY OF DAILY ACTIVITIES

Week

Details

1  Introduction session with the administration.  Briefing about the rules and history of this company. Also briefing about laws and safety regulations and equipment’s need to be wear during work.  Go to office to settle about thumbprint and send feedback letter from factory to Industrial Training Unit.  Supervisor shown us certain places in the company. Brought

27th June 2016 – 30th June 2016

overall look workshop.  Description of duties by Mr. Zainuddin Bin Daud and tour around the work area and to recognize and learn the components in engine.  First assigned unit is Heavy Machinery Unit. For this unit, I have watched demonstration for final drive.  The technician gave details explanation on how final drive works and factors of why gear need to be change.  Problem: The sun gear wear. So, it need to be change to avoid accident and ensure the vehicle run smoothly.

Figure 3.36 Gear

42

2  Learn about the components of the engine.  Besides that, technician shows us the demonstration of overhauled engine in light vehicle.  Innovation project of oil trap water separator. 3th July – 5th July 2016

 The purpose was to find the problem and we need to improve it.  The solution was we need to increase the level of oil trap in the drainage so that it will trap the water when the water flows through it.

3  In third week, I have been assigned to Light Vehicle Unit and was introduced to Head unit, Mohd Fadhli Bin Mohamad.

11th July 2016 – 14th July 2016

 I have been assigned to do the layout for control unit. We measure the parameter of the room and design it using software.  Besides, we’re in progress do the oil trap water separation project.  Other than that, we have been given a detail explanation on factors of underpowered engine.  The factors are mainly because of piston ring wear and valve’s leak.  If the piston ring wears, it needs to be change.  Then, factors of valve leak are because it is not properly closed which can cause scratch on valve and there will be oxygen out.

43

4  Cleaning workshop.  Self-study on final drive, automatic gearbox and engine overhaul.  Given a mini project which was workshop layout innovation.  We are needed to change and improved the old layout of heavy machinery and vehicle unit. 17th July 2016 – 21th July 2016

 The layout was drawn by using Catia software.  I have been assigned to sketch the old layout of heavy machinery and vehicle unit.

Figure 3.37 Workshop Layout

5  During this week, I have been assigned to Vehicle Test Line (VTL) unit. 24th July 2016– 28th July 2016

 Briefing by Mr Anuar in Vehicle Testing Line Unit (VTL).  He shows around the workshop and gave details explanation on each test of the car.  Demonstration on smoke tester. The smoke tester purpose is to detect the pollution of smoke emitted from the vehicle.  If the results of the test is higher than 50, the car will be issued by environmental department.  We have been given new mini project which is oil drum storage by supervisor.  The purpose of this project is to change the oil drum in the 44

storage, easy to keep the oil drum and to ensure the safety of the workers.

6 

Inspection on vehicle like Toyota Hilux, Nissan Urvan, Toyota Fortuner 2.5G

31st July 2016 – 4th August 2016



Only Nissan Nevara passed all test during the inspection while other vehicle had failed.



The vehicle failed the test if it didn’t pass the range or limit that had been assigned.



As for the Nissan Urvan, it didn’t pass the test because the result of front brake is less than 50%.



While for Toyota Hilux, it didn’t pass the test because the result of rear brake is less than 50%



Vehicle that didn’t pass the test will be send to the service center for services

7 

At 7th week, I have been assigned to Building Maintenance Unit.



Briefing given by Mr Azi Izwan and he gave me task to be

7th August 2016 – 11th August 2016

completed within a week. 

Task was mainly about air conditioning system, organizational chart in Jabatan Kerja Raya and function of each department in JKR.



During this week, I have been prepared for Industrial Training presentation as there would be lecturer visit. - Log book - Slide Presentation - Report



I did self-study on fire fighting system and installation of ceiling cassette split type air conditioner (E series) Acson.

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8 

Mr Zulfadli brought us to Air Cond Workshop unit. He gave us

14th August 2016 – 18th August 2016

briefing and details about this unit. 

Besides, he introduced us to the staff of this unit.



Clean the workshop and arrange tools.



Did self-study on installation of wall mounted split type air conditioner.



Wall mounted split type air conditioner usually used in hotels, houses and small room.



Other than that, I have been given task by my supervisor to managed files for Audit visit from main branch.



During this week, we have meeting with our supervisor to discuss for new project about innovation.



We need to come up with new idea to innovate any tools in workshop.



Divided into three groups.



I have been assigned to Project Unit and Mr Zamri gave briefing

21st August 2016 – 25th August 2016

9

about this unit. 

He introduced me to staffs of this unit.



Given task to study about fire fighting system 

Wet riser system



Dry riser system



Hose reel system



Meeting with supervisor and other trainee.



We were given quizzes and task.

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10 

Study on do’s and do not’s in installation of mechanical system in air conditioning system.



Final meeting with our supervisor to discuss about our final

28th August 2016 – 1st September2016

project. 

Each group need to present their ideas. 

1st group: circuit breaker to avoid electrical waste



2nd group: smart toolbox and air-conditioning filter.



3rd group: oil jet and tool dispenser.



After discussion, my group idea which was 3rd group chosen.



Oil jet function as to keep oil from spill onto the floor during repairing the vehicle. We created this oil jet as automatic hydraulic and can be control by remote.

Figure 3.38 Oil Jet (Sketch) 

For tool dispenser, it acts like washing machine but for tools. It is easy for technician to use tools.

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CHAPTER 4

CONCLUSION AND RECOMMENDATION

4.1 CONCLUSION In conclusion, after undergo three months of Industrial Training, all the objectives of the program are full-filled. I have learned lot of new things and have acquired sufficient exposure in new area such as instrumentation, Mechanical and others. I also have a chance to relate all the theories learned at university with real working life. Basically the program was successfully completed whereby all the objectives highlighted by Industrial Training Committee were achieved. I had the opportunity to integrate theory with practice while completing the assignment and projects given by my supervisor. The integration of the theoretical knowledge and the industry has enhanced better understanding on the subjects that I have learned in the university, thus smoothen the learning process. Moreover, the program was not only beneficial for me in term of technical or academic base but I could also develop various skills. From this program, I had developed skills in work ethics, communication and management skills. Since there are different levels of personnel, I had experience in adapting to this kind of environment. Jabatan Kerja Raya is an ideal place for Industrial Training Programme as the experience and knowledge gained is the most valuable lesson which cannot be received in class. The combination of technical and non-technical skills has provided an opportunity for the student to prepare in working life culture.

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4.2 RECOMMENDATION

During industrial training, I had been given ample opportunity to learn and experience working in corporate organization, I feel that there are rooms for further improvement so that I can meet the requirements of their practical placements particularly in fulfilling the objectives of the placement; as such I would like to make some recommendations for both JABATAN KERJA RAYA (JKR) and UMP.

In order for the next candidates to gain better knowledge and experience of working environment from the Industrial Internship Program, I would like to suggest some recommendations to be reviewed by industry unit of University Malaysia Pahang.

The time given for me to do industrial training is very short which only ten weeks. I would like to suggest for the Mechanical Faculty or UMP to extend two more weeks. This is because most of company only want to take students with 3 months industrial training. With this, it would be lack of opportunities for us to be chosen. Besides that, from my experience, I couldn’t been assigned to other department as I have only short amount of time.

Other than that, the briefing for Industrial Training should be given one semester before the search is on. The appropriate verification letter should be given to student before their semester break so they could search and apply for internship during their holiday. The list of company previous student had done their internship should also be publish to make the job of applying internship easier. Almost all University students in Malaysia is applying to do internship in the same period of time UMP student, so the faster they apply the better chances they get the placement.

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REFERENCES

1. Jabatan Kerja Raya Manual Pengendalian(v1.0) (Vehicle Inspection Station) 2. Industrial Training Guideline Handbooks 3. Notes 4. Books from Jabatan Kerja Raya

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