Industrial Training Report

DEPARTMENT OF CHEMICAL ENGINEERING KKEK3192: INDUSTRIAL TRAINING SEMESTER 3 2016/2017 19TH JUNE 2017 – 25TH AUGUST 2017 FINAL REPORT UNIGEL COMPOUNDS SDN BHD (SUBSIDIARY OF OPCOM HOLDINGS BERHAD) 11, JALAN UTAS 15/7, SHAH ALAM, 40200 SELANGOR DARUL EHSAN

NAME: MUHAMMAD SYUKRI BIN ABD RAHMAN MATRIC NUMBER: KEK140024

SUPERVISOR: DR. MAHAR DIANA HAMID COORDINATOR: ASSOCIATE PROF. DR. NGOH GEK CHENG

Disclosure

This is to confirm that I have read the report and that the information enclosed is correct and contain no confidential information.

Company: ____________________________________ Supervisor’s Name: ____________________________ Supervisor’s Signature and Stamp:

Date: ____________________

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Acknowledgement

I would like to express my utmost gratitude to everyone in Unigel Compounds Sdn. Bhd. for their dedications in teaching and assisting me throughout the whole duration of my industrial training here in this company. Their magnanimous contributions in term of knowledges and skills had made my internship experience so much more valuable that I had anticipated. A very incomparable and unique experience I believe I would never get elsewhere.

Likewise, I would like to thank Associate Prof. Dr. Ngoh Gek Cheng who has been there from the start and still all the way till now helping and assisting me to solve all the problems emerged from this course. Subsequently, much thanks to Dr. Mahar Diana for allocating time to visit and supervise my progress here in Unigel while sharing engaging insights that helps me to connect the experience here with my classroom learning, hence, making my internship here much more fulfilling.

Last but not least, undivided trust, understanding and helps from my family, friends, course mates, seniors and intern mates are very much appreciated. Without them, this internship would not be as meaningful as it feels right now.

Thank you and god bless.

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Table of content

Content Disclosure 1 Acknowledgement 2 Abstract 4 1. Learning outcomes 5 2. Company overview 2.1 Company profile 6 2.2 Policy statement 2.2.1 Quality commitment 7 2.2.2 Vision 7 2.2.3 Objectives 7 2.2.4 Customers and product quality 7 2.3 Quality objectives 8 2.4 Organization chart 10 3. Overall system 3.1 System overview 11 3.2 Product overview 3.2.1 Thixotropic gel 12 3.2.2 Product classification and comparison 13 4. Laboratory 4.1 Laboratory overview 14 4.2 Research and development (R&D) 15 4.3 Quality assurance 16 4.4 Tests used for quality assurance 4.4.1 Visual test and flash point test 17 4.4.2 Viscosity test 18 4.4.3 Drop point test 19 4.4.4 Oil separation and volatile loss test 20 4.4.5 Cone penetration test 21 4.4.6 Oxidation induction time test 22 5. Production 5.1 Production overview 23 5.2 Material management 5.2.1 Petroleum-based oil 24 5.2.2 Thermoplastic rubber 25 5.3 Process control 26 5.4 Assisting in maintenance 27 5.5 Product labelling 28 6. Warehouse 6.1 Warehouse overview 29 6.2 Logistics 30 6.3 Packaging 31 6.4 Product labelling 32 7. Skill acquired 33 8. Conclusion 34 9. References 34

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Abstract

As a third-year student pursuing a bachelor degree in Chemical Engineering, I am obligated to go for an industrial training to complete one of the prerequisite of this course in the third semester, specifically from 19th June 2017 to 25th August 2017. This program was meant to help in exposing myself to the real working life of chemical engineer and any working scopes that are related to this course. Thus, I will be equipped with hands-on experiences and new skills that I could use to polish my understandings while expand my awareness towards the engineering industries. My placement was a company that specialized in the production of thixotropic gel for optic fibre cable filling and flooding compound, Unigel Compounds Sdn Bhd. This company whom is a subsidiary of OPCOM Holdings Berhad, an optic fibre manufacturing company, assigned Mr. Shamsul Amri Abdul Manaf to supervise me for the whole internship period while Dr. Mahar Diana was assigned by Associate Prof. Dr. Ngoh Gek Cheng to be my supervisor from the Chemical Engineering Department of Engineering Faculty, University of Malaya. My generalized job scope in this company was to be involved in the whole production process of the gel, starting from the raw materials handling until the final product packaging. Along the way, I was exposed in quality assurance, process control, logistics and a lot of related hands-on experiences, valuable in every way, regardless of their respective fields. Thus, all the information and knowledge gained during my internship here in Unigel and how the new experience in this industry had help me for my own self development and future preparation are shared in this report.

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1. Learning outcomes

At the end of the course, the student will be able to: 1. Apply ethics and professional engineering practice in working environment. 2. Investigate engineering issues in related field towards lifelong learning. 3. Identify public health and safety issues in relevant engineering working environment. 4. Display team working spirit. 5. Demonstrate industrial related communication and presentation skills. 6. Formulate solutions for industrial related problems. 7. Examine the impact of engineering solution towards sustainable environment.

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2. Company overview

2.1. Company profile

Figure 1: Overview of Unigel Compounds Sdn. Bhd. principal and subsidiary companies.

Unigel Compounds Sdn. Bhd. or used to be known as OPCOM Niaga Sdn. Bhd. is one of the subsidiaries of OPCOM Holdings Berhad and a partial owner of Unigel (UK) Limited and Unigel IP Limited. OPCOM Holdings Berhad whom entirely owns Unigel Compounds Sdn. Bhd. works on building renting, provision of management services to subsidiaries and investment holding. Subsequently, the principal activities of Unigel Compounds Sdn. Bhd. is manufacturing and sales of cable filling and flooding compounds while Unigel (UK) Limited whom 40% owned by the former focuses on the same activities with addition of associated pumping and delivery equipment. Likewise, Unigel IP Limited whom also 40% owned by Unigel Compounds Sdn. Bhd. focuses on investment holding for the company. The approximate share value owned by Unigel Compounds Sdn. Bhd. for Unigel (UK) Limited is around RM11.65 million. Unigel (UK) Limited and Unigel IP Limited are both incorporated in United Kingdom and Hong Kong respectively. The current Chief Executive Officer for the company is Mr. Eric Chhoa Kwang Hua.

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2.2. Policy statement

2.2.1 Quality commitment

Everyone in Unigel is 100% committed towards the quality and the customer service. Moreover, quality is not just another goal, instead, it is a basic strategy for survival and sustainable growth while moving forward to being the “best” in the industry as a team.

2.2.2 Vision

Unigel embraces Total Quality Management (TQM). Pledging to satisfy the customer’s requirement through continuous improvement process. Understanding that TQM is long term commitment that aims to improve working methods while educating and training people, providing safer workplace, managing the business processes and selection and retention of supplier. Unigel also aims to expand the market to improve job security and better quality of life for all.

2.2.3 Objectives

Unigel focuses to supply high quality products, right on time and at the lowest cost possible for the customers. Also, Unigel will continue to improve each time an objective is achieved to stimulate further quality improvement once recognized and reset. Full dedication, commitment and teamwork will be instilled to maintain a constant focus on quality while reaching for the objectives.

2.2.4 Customers and product quality

Unigel knows the identity of the customers and their needs and will always try to meet and exceed their expectation. If any requirements are unclear, Unigel will try to gain better understanding at any mean necessary. If failure occurred, Unigel must determine the roots of the problem and ensure none of the problems will repeat themselves again. Quality comes first before cost and schedule. Peers or superiors’ actions or decisions can be questioned if they are somehow leading to reduction in quality of the products. 7

2.3 Quality objective

There are total of eight measurable quality goals and objectives that concur with the quality policy and overall needs of the organization which help in the efforts of continuous improvement and enhancing customer satisfaction.

1. Delivery precision The department of supply chain must ensure that the products shall always be delivered precisely on time. Any delay must be kept as minimum as possible.

2. To improve customer satisfaction Marketing department must measure the levels of customer satisfaction toward the products and services. They also must ensure that the feedback forms are prepared, distributed and collected by March 2018 and summarized by end of April 2018.

3. Customer complaints handling Marketing department and quality assurance department must keep the number of complaints on delivered products’ physical defects as minimum as possible during financial year. They also must ensure that the time taken from when a complaint is received until a written acknowledgement is sent to the costumer is within a working day.

4. To enhance supplier reliability Supply chain department must ensure that there is zero stock out on delivery precision of all supplied material, calculated as on time delivery.

5. Continuous improvement and innovation Human resource and administration department must provide training session for employees to upgrade their competence levels. This shall be done once a year for each employee.

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6. Meet customer specification Production department must ensure to achieve entirely against Purchase Order.

7. Minimize scrap Excess material remaining after the manufacturing process including unviable defect product must be kept as minimum as possible by the production department.

8. To provide good quality service to support production Engineering department must ensure seldom machines breakdown and totally commit to the scheduled preventive maintenance.

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2.4. Organization chart

Figure 2: Organization chart for Unigel Compounds Sdn. Bhd. as of July 1, 2017.

Based on this chart which was created on July 1, 2017 and approved on July 11, 2017, shows the overall institutional structure of Unigel Compounds Sdn. Bhd. As of the later date, there were 16 people working under this company as direct employees along with four support employees. However, from all of them, there were around ten people I had worked with during my internship, excluding my fellow industrial training students. Furthermore, I was placed under the supervision of Operations Manager, Encik Shamsul Amri Abdul Manaf whom would give out task order during daily roll call early in the morning. Subsequently, I would be by then placed either under production, warehouse or laboratory department for the rest of the day.

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3. Overall system

3.1. System overview

Figure 3: Department based flowchart for production of thixotropic gel.

The plant operates from 8:30 a.m. until 5:30 p.m. on weekdays and from 9:00 a.m. until 1:00 p.m. every first week Saturday each month. The whole production process of thixotropic gel only involves in physical reaction instead of chemical reaction where the raw materials are heated up and mixed until entirely homogenize. The raw materials import and product exports are both locally and globally bound. They are, however, required to undergo quality assurance tests before being proceeded to the next assigned process. This is to ensure that only the best quality is received and sold. 11

3.2. Product overview

3.2.1 Thixotropic gel

Figure 4: Location of gel filling and flooding inside a fibre optic cable. (Loose Tube Fibre Optic Cable, A Furukawa company, 2015)

So far, the only product made by Unigel Compounds Sdn. Bhd. is thixotropic gel. However, this product is made using different formulations of which led to different grades with different properties and is produced only upon customer’s demand for their own specialize purpose based on the properties. Thixotropic gel is a non-Newtonian pseudo plastic liquid with time-dependent shear thinning property. It is highly viscous and exhibit few properties that are highly beneficial for optic cables. These properties assist in ensuring the safety and working efficiency of the optic cables. These gels are produced as a filling and flooding compound inside a fibre optic cable. Filling and flooding have a rather the same kind of function but differs in term of location. Filling gel is applied in the cable core, meanwhile, flooding gel is applied between the core wrap and the outer protective casing or housing. They are specifically made to provide water and gas tightness for the cable in a wide range of temperature, location and environment.

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3.2.2 Product classification and comparison

The formulations of the thixotropic gel are differentiated based on the petroleum-based oil, antioxidant and antirust used for each formulation while are mixed along with sustained type of material used for thickener and de-crystallizer. Different formulation will be graded differently and will be produced solely based on customer’s demand. However, under the same grade, there are also different formulations which are differentiated by the materials used. Currently, these differences focused on the type and percentages of antirust mixed in the formulation.

Table 1: Example of different formulations under same thixotropic gel grade.

Grade A Oil Thickener De-crystallizer Antioxidant Antirust 1 Antirust 2 Total

F-A X1A X2A X3A X4A X5A 100

F-B X1B X2B X3B X4B X5B X6B 100

Tolerances ± 0.5 w% ± 0.5 w% 0 0 0 0 -

Based on latest R&D, only petroleum-based oil was determined suitable to be mixed with thixotropic gel and able to maintain it needed characteristics. The thickener is used to turn the mixture into gel-like liquid and is made of polymer under category of thermoplastic rubber. Antioxidant is used to prevent or retard the degradation of material caused by ozone specialized for plastics and rubber. It is a derivative of aniline. Antirust was added so that the cable metals that will be in contact with the gel will not corrode. Once the products are made, two samples of the gel are taken for testing before being either approved or rejected for loading. Each sample is approximately 1 litre of gel taken in metal tub. The samples are tested based on the viscosity. If the viscosity is in the given range provided by the company, the whole batch of the gel is approved. However, if the viscosity is out of range, the whole batch of the gel will be reworked until the new sample tested is within the needed viscosity range.

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4. Laboratory

4.1. Laboratory overview

Figure 5: Two ways of obtaining sample. Processing line 1 uses the first method (left picture) meanwhile processing line 2 and 3 use the second method (right picture).

Laboratory mainly focuses on the enhancement of the product quality or maintaining the ideality of the existing formulations. These are all can be achieved all the way from conducting research and development process to the sample testing for quality assurance. This department also handles the complaint received from the buyers by retesting the sample and hands the result over to the production and logistics departments for further action.

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4.2. Research and development (R&D)

Figure 6: Mixer (left) and vacuum (right) used during research and development process.

Research and development process was done with purpose to keep up with the latest technology in fibre optic elements and to find better formulation for thixotropic gel using new and better oil available in the market. If the new formulation created seems to be effective and economically sustainable after a wide range of quality tests, the formulation will be drafted to undergo further evaluation and consideration by the higher management. Other than different type of oil, different percentage of oil used in formulation also was done in R&D process as part of the same purpose. The type of oil ranges all the way from oleo to petroleum-based oil. As far as these processes go, it can be concluded that the petroleum-based oil is the most suitable oil to produce thixotropic gel while oleo is the least one due to certain defectiveness occurred such as oil separation at room temperature.

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4.3. Quality assurance

Table 2: Re-illustration and combination of two technical data sheets for different grades of gel. Grade B

Grade C

Properties

Specifications

Test Method

Specifications

Test Method

Appearance

Translucent

Visual

White

Visual

Color stability, 130 ℃, 120 hrs

< 2.5

ASTM D127

-

-

Density, 25℃ (g/ml)

0.8 - 0.9

ASTM D1475

0.45 ± 0.025

ASTM D1475

Flash point (℃)

≥ 200

ASTM D92

> 200

ASTM D92

Drop point (℃)

≥ 150

ASTM D 566-93

> 190

ASTM D 566

Cone penetration, 25℃ (dmm)

≥ 350

ASTM D 217

401 ± 20

ASTM D 217 (M)

Cone penetration, -40℃ (dmm)

≥ 230

ASTM D 217

> 160

ASTM D 217 (M)

Viscosity, 50 s-1, 25℃ (Pa.s)

4.3 - 6.3

CR Ramp 0-100 s-1

35 - 55

UNIGEL CR Ramp 0-12 s-1

Oil separation, 150℃, 24 hours (Wt %)

≤ 0.8

FTM 791(321)

Zero

FTM 791-321 (M)

Volatile loss, 150℃, 24 hours (Wt %)

≤ 1.0

FTM 791(321)

< 1.0

FTM 791-321 (M)

Oxidation OIT, 190℃ (min)

≥ 30

ASTM D3895

> 30

ASTM D3895

Acid value (mg KOH/g)

-

-

< 0.3

ASTM D974-85

H2 generation, 80℃, 24 hours (µl/g)

≤ 0.1

UNIGEL

≤ 0.02

UNIGEL

Water resistance, 20℃, 7 days

-

-

Pass

SH/TO453

Fungal growth

Nil

BS 5980

Nil

BS 5980

Relative permittivity, 1 MHz, 25℃

-

-

≤ 0.8

ASTM D150 ASTM D257 ASTM D924

Volume resistivity, 23℃ (ohms.cm)

-

-

19x1014

Dissipation factor, 1 MHz

-

-

4.4x10-4

Table 2 illustrates some kind of quality “benchmarks” for two of their products which were drafted by the laboratory for quality assurance purposes. Upon receiving the sample from the intended processing unit, this sample will be tested and compared according to their specifications. If the result lies within the needed range, the product will be a go for packaging and export. However, if not, the gel will need to be reworked until it reaches the desired properties. Sample testing for approval can either be instantaneous or delayed. This may be caused by the procedure needed for each test or it necessity in the production itself. All of which affected from buyer’s demand and process economy. So far, most prominent test is the determination of product viscosity. This test is also the only instantaneous test that decides if the product is ready to be discharged for packaging or in need for reworking. The rest however, due to their procedures or/and necessity in the production, will be ran later or upon which they are critically needed. E.g.: upon receiving complaint.

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4.4 Tests used for quality assurance

4.4.1. Visual test and flash point test

Figure 7: Equipment used to determine the flash point of newly arrived oil.

Flash point test is run each time new petroleum-based oil arrives. Apart from visual test using evaluator own’s naked eyes, this is one of the compulsory procedures to determine whether the oil is suitable for production or the other way around. If the test gives a positive result, the oil is then ready to be discharged from the oil tank into the designated containers. Meanwhile, if the result is negative, the oil will be sent back to the supplier and a new batch of oil will be delivered as earliest possible to avoid any delay in the production. The benchmarks for visual test consist of the colour of the oil and the presence of any unwanted debris inside the liquid whilst for flash point test, the most common and averaged benchmark would be the temperature where the oil started to burn, approximately at least at 220℃.

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4.4.2. Viscosity test

Figure 8: Rheometer used to run the viscosity test.

Viscosity test is considerably the most crucial test of all the tests during production process. This test is the ultimate “go” or “no” for the production process of the gel and the discharging process of the gel into designated containers. This property correlates itself to other properties that the viscosity test itself is enough to be the one who speaks first for the whole production process before other tests provide more detailed information on the gel produced. As exampled in the table 2, if the viscosity of the gel produced falls into the provided range, the process is a go and the gel is ready to be discharged. Meanwhile, if it is the other way around, the gel need to be reworked until its viscosity falls into the range.

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4.4.3. Drop point test

Figure 9: Depiction of ongoing drop point test process.

Drop point test aims to determine the melting point of the gel. This was done by filling the gel into a small semi-sphere container with holes at the larger part of the semi sphere and another at the tip of the container. The gel is formed into a cone shape and placed inside a test tube. The test tube is then submerged inside silicone oil placed inside a larger beaker. Two thermometers are used in this process. One is placed inside the test tube, slightly above the gel container, meanwhile, another one is submerged into the silicone oil. The silicone oil is then gradually heated with help from magnetic rotator to homogenize the heat distribution through the oil and to increase the efficiency of heat transfer from the silicone oil to the gel container. Once the gel melt and drop through the hole at the tip of the cone, both reading of the thermometers are taken and the average is calculated. 𝑇𝑑𝑝 =

𝑇𝑡𝑡 + 𝑇𝑠𝑜 2

Where, Tdp = drop point temperature, Ttt = test tube temperature, Tso = silicone oil temperature.

The averaged drop point temperature for these gels would usually be around 200℃. If the gels started to drop below their own specific temperature, the gels are presumably considered as failed products. 19

4.4.4. Oil separation and volatile loss test

Figure 10: Depiction of the apparatus coordination. Before test (left), the oven used (middle) and after test (right).

This test determines whether the gel produced will discharge oil under extreme condition. Referring to table 2, a sample with amount between 9.8 to 10.2 grams will undergo 24 hours heating process at temperature more than 100℃. Subsequently, the quality of the sample will then be evaluated visually to determine oil separation while physical evaluation was done to determine volatile loss. Visual evaluation consists of checking whether there is a present of yellow liquid at the bottom of the beaker or/and any leakage from the porous cone occurred after the process. If there is a leakage occurred as depicted in figure 10, the test is still considered pass but this shows that the gel is not at its highest quality. However, if there is a yellow liquid discharged at the bottom of the beaker, the gel is considered a failed product due to the occurrence of oil separation. For volatile loss test, the weight of the gel along with the apparatus are weighted for before and after test. If there is a weight differences, this shows that the gel had evaporated during the heating process. However, if the evaporation amount is still below the specified maximum value, the gel is still considered an ideal product to sell.

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4.4.5. Cone penetration test

Figure 11: Depiction of a tub containing thixotropic gel undergoing cone penetration test.

To be working at full capacity, the gel must withstand any harsh condition including cold weather. Thus, due to this factor, the gel is formulated with antifreeze to stop it from turning solid under cold weather of which can cause the fibre optic cable to break easily. To test the probability of this condition to occur on the gel, cone penetration test is done to every batch of gel produced by the company. The gel is placed inside a designated tub and stored in a freezer for 24 hours at the temperature approximately around -40℃. The tip of the cone is then placed slightly above the gel before the whole cone is released and fell into the liquid. The best indication on the quality of the gel would be when the cone falls as low as it can be. This shows that there is not much of resistance caused by the frozen gel and the gel manages to stay in liquid phase even after undergoing extremely cold temperature exposure. This test is also done at room temperature (25℃) to make sure that the gel is behaving ideally at the particular condition and also to act as a benchmark used to be compared with the test at the extreme condition. The gel at the normal condition must never be defrosted or heated before this test is done.

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4.4.6. Oxidation induction time test

Figure 12: Equipment used for oxidation-induction time test.

Oxidation of the gel can cause severe deteriorations toward the mechanical strength and electrical properties of the fibre optic cable. Hence, this negative perpetration need to be detected and contained before any unwanted effect happened. This detection process can be done by running an oxidation induction time test using equipment as in figure 12. This equipment works by heating a sample with weight between 9.5 mg to 10.5 mg under Nitrogen atmosphere at temperature of 190℃. The atmosphere is then changed to Oxygen. Upon this change, the time from the gas change to the observed exothermic peak is observed. During this brief, the oxidation time is measured. This process runs for 100 minutes with both Oxygen and Nitrogen flow at the rate of 50 ml/min.

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5. Production

5.1 Production overview

Figure 13: Simplified illustration of the common pathways for the whole production process.

Production department involves mainly on the formulation of thixotropic gel. Handling materials starting from their raw and unmixed conditions until the formation of the final product. This department need to make sure that the product produced follows the formulation provided by the company and any other production standards and regulations set by the law. This department is also in charge in minimizing cost, safety regulations and any other task that helps to ensure the plant wellbeing along with its workers.

5.2 Material management

When it comes to raw materials, some of them can be stored inside common containers and can be easily handled as usual. However, there are also some of the raw materials, which will be specified below, need to be stored inside their own specialize container or be prepared for production differently from their own consanguine due to certain factors.

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5.2.1 Petroleum-based oil

Figure 14: Storage tanks (left) is used to store Korean oil while IBC container (right) is used to store Qatar oil.

Currently, there are two main petroleum-based oils used in the formulation of Unigel’s products of which both are stored in different type and size of containers due certain factors. The two oils are represented as Qatar oil and Korean oil. The storage tanks that store Korean oil are made of metal and large in capacities. Meanwhile, the IBC containers that store Qatar oil are made of plastic-polymer type of compounds and critically smaller than the storage tanks. Although around 15± IBC containers are used to store Qatar oil for each batch arrived. The factor on the bulkiness of oil ordered for production can still be included as part of storage selection factor and furthermore be considered as the main factor due to the summation of all the IBC containers’ capacities used for Qatar oil is still way less than a storage tank for Korean oil. One IBC container can hold around 500+ kg liquid, while, one storage tank can hold around 24000 litres of liquid with weight approximately around 24 metric tons. Other factors that can be considered are the composition of oils that affect their physical and chemical properties and the quality of oil.

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5.2.2 Thermoplastic rubber

Figure 15: Grinding process of thermoplastic rubber.

Thermoplastic rubber is a type of polymer used as a thickener to turn the mixture into a gel. There are two brands used by Unigel for thickener, of which both are made from the same compound. However, the polymer from one of the brand need to be grinded first before being loaded into the processing tank. This is because the polymer from that particular brand are somehow harder and more compact than the other one. Potential reasonings of this condition could be due to the packaging of the polymers and their qualities. Polymer that needed grinding is packed using plastic while the other brand is packed using paper. These packaging may cause different electrostatic interaction between the polymer particles of which the plastic packaging might has higher attractive electrostatic force, hence, making it more compact and harder to break. Difference in the quality of the polymer from both brands, undetermined which one is better or lesser, could also be a considering factor of why one brand is harder while the other is softer.

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5.3 Process control

Figure 16: A re-illustrated image of the storage tank system for Korean oil.

Supervisory control and data acquisition (SCADA) software is used for the whole production process. Starting from Korean oil storage tank to the final gel discharging process into the drum barrels or IBC containers. The software controls most physical properties such as volume, temperature, pressure and weight. However, as the storage tanks in figure 17 are located outside of the plant, while the control room is in the inside, manual control had to be implemented in the time of short-staffed. One way is that, a translucent pipe was installed on each tank to determine that the lower tank is about to overflow. Once the pipes indicate the said situation, the valve above the lower tank is closed so the oil can be filled inside the higher storage tank. Optimum volumetric usage for each tank is around 95% to avoid overflow and over-pressurized tank conditions.

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5.4 Assisting in maintenance

Figure 17: Maintenance on air spray gun piping system.

As according to the eighth 2.3 Quality objective, maintenance is critically needed to be at constant alert to avoid any machine breakdown that can adversely affects the production process. Thus, scheduled maintenance is set up to prevent such problem from having any fortuity to occur. Maintenance also helps in making ease of the production process by providing easier and user-friendly system for the workers in the plant. Thus, this inadvertently helps in increasing the efficiency of the production process. Being a part of this task somehow gave me a chance to correlate the smaller details into a bigger picture. It also made me realise that everything matters even to the smallest feature and helps to complete each other in ways that are systematic and organize.

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5.5 Production labelling

Figure 18: The position of labels for both production and warehouse departments on a re-illustrated drum barrel.

Figure 19: Re-illustrated and generalised version of production labelling.

Production labelling solely focus on the product details. This helps to avoid reopening of the barrel drum in case of product confusion occurred after packing. The labelling process usually was done after the product is loaded into the drum barrels or IBC containers or before the lid of the drum is sealed and locked. QR code printed along with the label directs the scanner to the batch number of the product when scanned. In a way, this feature provides confirmation and security for the customers while inadvertently, makes their logistics procedure much easier.

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6. Warehouse

6.1 Warehouse overview

Figure 20: Depiction of oil discharging process. The cable is disconnected from the hose that is used as an inlet to storage tanks.

Warehouse mainly focuses on pre-and post-production process. They are usually involved partially in documentation and entirely in physical work for raw materials import and product exports. For pre-production process, upon receiving the raw materials, especially, the petroleum-based oil, warehouse will start to discharge the oil to the designated container (IBC or storage tanks) once the laboratory has proven the quality of the oil to be satisfying. If not, they will need to send back the oil to the supplier and arrange for new oil arrivals at the earliest. Meanwhile, for post-production process, warehouse would pack the barrel drums or IBC containers and load them into the container lorry for global export. They would also put another label on those products that specify mainly on the export process and comply to the regulations made by the customers, company and the Malaysian customs.

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6.2 Logistics

Logistics mostly handle the documentations of the raw materials import and products export. Both of which are connected globally and locally toward this company. The raw materials are commonly imported from Korea, China and USA for petroleumbased oil and thermoplastic rubber. Meanwhile, the products are exported to fibre optic cable manufacturing companies nationwide. Some of the countries Unigel had their exports to are Indonesia, India, Australia, Russia, United Emirates Arab and USA. Locally, these gels are mainly ordered by the sister company, OPCOM Cables Sdn. Bhd., and a cable company in Penang. Even before the products are packed and until to the extent of products loading into the container, logistics must make sure that the warehouse labelling is tally to the product being produced (grade, batch number etc) by the production department while getting up to date with the requirements and changes made by the company, customers and the Malaysian customs. In any case of error in this section, the products will be barred from shipping by the customs and the products will be subjected to complex procedures for passing process.

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6.3 Packaging

Figure 21: Completely packaged barrel drums ready to export (left) and the arrangement of the drums inside the container lorry(right).

Before export, product packaging is one of the most important processes and need to be attended with careful manners. This procedure ensures the safety and security of the product during shipment. Compared to IBC containers, barrel drums have a far more complicated packaging procedure as depicted in figure 22. This is due to the complex approach needed to make sure that the barrel drums stay together on the pallet without sliding through or getting apart during travel. The procedure starts with the metal straps are strapped around the drums horizontally while the drums are then strapped to the pallet vertically using a specialize tool. This procedure is used to bring the drums closer to each other and in the meanwhile, helps to lock the drum to the pallet respectively. Next, after ensuring that the warehouse labelling is pasted onto the drums, the strapped drums are then wrapped using a translucent plastic wrapper as final protective layer. This somehow helps to keep the metal straps from getting loose in the case of unexpected turbulence and to prevent the drums from getting scratched during delivery. Finally, the fully packed drums can now be loaded into the container lorry and ready to be exported nationwide.

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6.4 Product labelling

Figure 22: Re-illustrated example of warehouse labelling.

Warehouse labelling solely focus on the logistics of the product. The details of the label usually consist of what already is inside the production labelling but added with buyer’s details and demanded amount of barrel drums or IBC containers. Analysis of these labels can generate so much information such as potential market and optimisation of future productions. The labelling process usually was done after the product is loaded into the warehouse or before the drums are wrapped for export.

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7. Skill acquired

I.

Self-discovery initiative Inquiring direct employees and text book learning can only go so far. Thus, due to these limitations, I started to develop a self-discovery initiative in search of ways to fill in the gap between information so that I could gain complete understand of the system I was aiming to learn. E.g.: checking the control system myself to understand the whole production process of the gel and correlate them to the lab scale gel making process (R&D process).

II.

Adaptive work skills Adaptive work is the change in method or strategy when the existing one is unfitting to the current situation. This requires problem analysis on the existing solution which lead to new learning. I gain quite an increment in this skill when I was working the warehouse where my capability to do the physical work was limited. Thus, some of the works were made easier after certain levels of observation and “try and error” analysis.

III.

Basic laboratory analysis grasp When I was assigned in the laboratory, I was introduced with several equipment and laboratorial procedures in an instant. This situation was very different as compared to what I had faced in university where I was given time to study only an equipment each time and yet was further familiarized by the technician through assisted learning. However, during this internship, I somehow gain better efficiency in grasping information related to laboratory. This would surely benefit in a long run especially during my final year research project period.

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8. Conclusion

In conclusion, this 10 weeks of internship provides me with such an eye-opening experience and a highly valuable insight of what I might face in my future career as a chemical engineer. To quote Rita Mae Brown, an Emmy-nominated screenwriter, “Good judgment comes from experience, and experience comes from bad judgment.” I believe that experience truly is the best teacher of all no matter how they came or from who they came from. Thus, from this experience, it made me realizes that everyone must equip themselves with a bit of everything when running something as huge as a chemical plant. This is considerably important to avoid delay or malfunction in the system or organization when a sudden uncertainty comes unsuspecting. Consequently, it made me more appreciative toward every knowledge that I gained during internship regardless whether they are a part of chemical engineering or any other fields. Undoubtedly, a knowledge today could become a valuable experience tomorrow.

9. References

[1] Cable Filling / Flooding Compounds. (n.d.). Retrieved August 1, 2017, from http://www.marcusoil.com/product/cable-filling-flooding-compounds/ [2] Guillaume-Koene, E. (2016, November 1). Six Principles for Leading Adaptive Work. Retrieved August 05, 2017, from http://network.crcna.org/classis/six-principles-leading-adaptive-work [3] Lakshmanan, P. R., & Tayebianpour, A. (June 5, 1995). U.S. Patent No. 5 728 754. Washington, DC: U.S. Patent and Trademark Office. [4] Malaysia's Opcom to buy 40% stake in UK supplier Unigel. (2014, July 31). Retrieved August 02, 2017, from http://www.thestar.com.my/business/business-news/2014/07/31/opcom-tobuy-strategic-stake-in-supplier/ [5] Organisation Structure. (n.d.). Retrieved August 2, 2017, from http://www.opcom.com.my/corporate-information/corporateinformation/corporate-structure [6] Oxidation Induction Time Measurements by DSC [PDF]. (1988, October). Tokyo: Hitachi High-Tech Science Corporation. [7] Technical characteristics of fiber optic cable [PDF]. (2015). Ofs Sviazstroy- 1 Fiber Optic Cable Company. [8] Unigel Compounds Sdn Bhd: Company Profile - Bloomberg. (n.d.). Retrieved August 02, 2017, from https://www.bloomberg.com/profiles/companies/1359964D:MK-unigelcompounds-sdn-bhd 34